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1.生產(chǎn)規(guī)模、生產(chǎn)方法與水泥品種Production scale, production method and cement types

1.1生產(chǎn)方法 Production method

干法生產(chǎn)，設(shè)置一條φ3.5×54m帶窯外分解爐五級旋風(fēng)預(yù)熱器回轉(zhuǎn)窯生產(chǎn)線。

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生產(chǎn)能力及工廠規(guī)模Production scale and capacity

   燒成系統(tǒng)生產(chǎn)能力為日產(chǎn)熟料1500噸，摻加石膏后工廠年產(chǎn)硅酸鹽水泥500000噸。

The production capacity is 1500t/d for clinker, while 500,000t/a for Portland cement when mixed with gypsum.

1.3 水泥品種 Cement types

本技術(shù)和設(shè)備可生產(chǎn)符合中國水泥標(biāo)準(zhǔn)GB175-1999中的硅酸鹽水泥,其強(qiáng)度為32.5MP、42.5MP，可根據(jù)市場需要進(jìn)行調(diào)節(jié)。

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.原料燃料與配料

2.1.Raw materials properties chemical composition

 

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配料計(jì)算

本生產(chǎn)線采用一臺Ф3.5×54m五級旋風(fēng)預(yù)熱器帶分解爐回轉(zhuǎn)窯，熟料臺時(shí)產(chǎn)量62.5t/h，熟料熱耗850Kcal/kg （3552.0KJ/kg）熟料，根據(jù)所列各種原料化學(xué)成分進(jìn)行配料計(jì)算。

配料計(jì)算

⑴ 熟料熱耗指標(biāo)：  

熟料單位熱耗：850Kcal/kg.cl  熟料實(shí)物重油：960kg/t.cl

⑵ 熟料率值設(shè)計(jì)指標(biāo)： KH=0.89±0.02   SM=2.6±0.1           IM=1.5±0.1

⑶ 原料配合比例：

針對業(yè)主提供的原料進(jìn)行配比不能滿足配料要求，需要增加鐵質(zhì)原料，鑒于業(yè)主沒有提供相關(guān)鐵質(zhì)原料，配料中設(shè)定鐵質(zhì)原料成分進(jìn)行配料。擬采用石灰石、粘土、砂、鐵粉四組份配料。

According to raw material and fuel conditions, the following materials will be used for material blending: limestone, Silica, and iron powder.

 

⑷ 生料、熟料化學(xué)成分

⑸ 熟料礦物組成

⑹ 熟料率值：KH=0.886   SM=2.53    IM=1.64

⑺ 熟料理論料耗：熟料理論料耗為1.556噸生料/噸熟料

⑻ 物料平衡   

物料平衡計(jì)算，根據(jù)回轉(zhuǎn)窯臺時(shí)產(chǎn)量62.50噸，年運(yùn)轉(zhuǎn)率82%，熟料實(shí)際料耗1.620噸生料/噸熟料，熟料燒成系統(tǒng)單位熱耗840Kcal/kg.cl（3511.0KJ/kg），燃料熱值9000 kcal/kg(37620kJ/kg)等工藝指標(biāo)和配料計(jì)算中的原料配合比例進(jìn)行，物料平衡計(jì)算結(jié)果列于表一：

3. 工藝設(shè)計(jì)特點(diǎn)Main technical characteristics

3.1 為保證系統(tǒng)運(yùn)轉(zhuǎn)率，提高產(chǎn)品產(chǎn)、質(zhì)量，設(shè)計(jì)中大量選用了具有二十世紀(jì)九十年代先進(jìn)水平的新設(shè)備、新工藝，以提高生產(chǎn)線的裝備水平，確保設(shè)計(jì)指標(biāo)的實(shí)現(xiàn)。如新型五級旋風(fēng)預(yù)熱預(yù)分解系統(tǒng)、高效空氣梁篦冷機(jī)，節(jié)能型多通道噴煤管，戴維森高溫風(fēng)機(jī)，魯奇最新技術(shù)生產(chǎn)的電收塵（BS930）等，輸送設(shè)備采用了耐用、節(jié)電的板鏈提升機(jī)、鏈?zhǔn)捷斔蜋C(jī)，將使本工程的裝備在同規(guī)模生產(chǎn)線中處于領(lǐng)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 在保證生產(chǎn)線的完整性、生產(chǎn)的連續(xù)性和可靠性的前提下，力求簡化生產(chǎn)工藝流程，以便于生產(chǎn)管理，減少生產(chǎn)事故點(diǎn)，降低投資。

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 工藝布置上，簡化設(shè)備廠房，減少建筑面積 Simplifying houses for equipment to decrease building area

庫頂露天布置；高溫風(fēng)機(jī)露天布置；帶式輸送機(jī)通廊不設(shè)屋頂，用玻璃鋼防雨罩防雨；取消提升機(jī)樓；收塵器露天放置。

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.

對各種原料、半成品和成品，在滿足正常生產(chǎn)要求的前提下，合理減少儲(chǔ)存期，并盡量采用堆棚儲(chǔ)存。土建費(fèi)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.

改進(jìn)窯尾工藝布置，窯尾預(yù)熱器塔架設(shè)計(jì)為鋼結(jié)構(gòu)，既可加快施工安裝進(jìn)度，節(jié)省投資，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 充分考慮節(jié)能、降耗，生料入窯使用節(jié)能型的板鏈?zhǔn)教嵘龣C(jī)和空氣輸送斜槽，提高了系統(tǒng)的運(yùn)行可靠性，降低了輸送能耗。

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 加強(qiáng)計(jì)量。除生料配料采用電子皮帶秤計(jì)量外，各進(jìn)廠原料、入窯生料、入窯煤粉、出窯熟料、出庫熟料都設(shè)置了相應(yīng)的專用計(jì)量設(shè)備，為工廠的科學(xué)管理提供了依據(jù)。

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 保護(hù)環(huán)境，采取有效措施嚴(yán)格控制排放廢氣的含塵濃度在規(guī)定范圍內(nèi)。在生產(chǎn)工序中的各揚(yáng)塵點(diǎn)，針對不同的廢氣特性，設(shè)置與之相應(yīng)的新型高效專用收塵設(shè)備。

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.技術(shù)方案Technical plan

4.1 生產(chǎn)工藝Production process

4.1.1 生產(chǎn)規(guī)模、生產(chǎn)方法與產(chǎn)品方案Production scale, production method and product plan

本項(xiàng)目采用新型干法生產(chǎn)工藝，建設(shè)一條日產(chǎn)1500噸熟料的新型干法水泥生產(chǎn)線。采用φ3.5×54m回轉(zhuǎn)窯煅燒，窯尾采用帶五級旋風(fēng)預(yù)熱器和分解爐的預(yù)熱分解系統(tǒng)。

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 主機(jī)設(shè)備選型和主要生產(chǎn)設(shè)施配置Selection of main equipment and production facilities

4.1.2.1 石灰石破碎Limestone crushing

石灰石破碎選用單段錘式破碎機(jī)，本破碎機(jī)適用于破碎中等強(qiáng)度的脆性礦石，如石灰石、泥灰?guī)r、頁巖、石膏和煤等，入料粒度大，可一次將大塊原礦破碎到符合入磨粒度。此外，由于本機(jī)采用順向排料篦子，對礦石中的水分和泥土有更強(qiáng)的適應(yīng)性。本機(jī)具有特殊的進(jìn)鐵保護(hù)，對混入機(jī)內(nèi)不能破碎的金屬異物，將反彈到給料機(jī)上，操作人員可根據(jù)異樣金屬聲停機(jī)處理。

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.     

本項(xiàng)目石灰石破碎采用TKPC16.18單段錘式破碎機(jī)，給料粒度800mm，生產(chǎn)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

對1500t/d生產(chǎn)線而言，生料粉磨可供選擇的有HRM2800m立磨粉磨系統(tǒng)。

For 1500t/d cement production line, available raw mill system is HRM2800m mill system.

4.1.2.3 生料均化與儲(chǔ)存Raw meal homogenizing and storage

本設(shè)計(jì)采用一座集生料儲(chǔ)存、均化于一體的φ15×50mMF均化庫，生料儲(chǔ)量6500t，儲(chǔ)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 燒成系統(tǒng) Clinkering system

熟料燒成采用一套單列五級CDC預(yù)分解系統(tǒng)、φ3.5×54m回轉(zhuǎn)窯和第三代新型空氣梁篦式冷卻機(jī)等設(shè)備組成的窯外分解煅燒系統(tǒng)。日產(chǎn)熟料1500t/d，熟料燒成熱耗840Kcal/kg （3511.0KJ/kg），入窯生料的碳酸鈣分解率大于90%。系統(tǒng)廢氣余熱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.

熟料冷卻采用引進(jìn)技術(shù)、中國制造的新型第三代空氣梁篦冷機(jī)，篦床有效面積為61.8m2，產(chǎn)量62.5t/h，出冷卻機(jī)的熟料溫度為環(huán)境溫度＋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

本項(xiàng)目水泥粉磨選用兩臺φ3.5×13m管磨，配置N-1500型O-SEPA高效空氣選粉機(jī)組成圈流粉磨系統(tǒng)，臺時(shí)產(chǎn)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工藝主機(jī)設(shè)備表List of main equipment

 

4.1.4 生產(chǎn)工藝過程Process procedures

4.1.4.1 石灰石破碎及預(yù)均化Limestone crushing and pre-homogenizing

石灰石破碎站設(shè)在廠區(qū)，采用單段破碎系統(tǒng)，其工藝流程為：礦區(qū)開采的石灰石由汽車運(yùn)輸進(jìn)廠，卸入破碎站內(nèi)石灰石料倉，經(jīng)料倉下可調(diào)速的重型板式給料機(jī)喂入TKPC16.18錘式破碎機(jī)進(jìn)行破碎，破碎機(jī)額定產(chǎn)量為250噸/時(shí)，破碎后的礦石（粒度≤25mm）由出料帶式輸送機(jī)輸送入石灰石預(yù)均化堆場進(jìn)行預(yù)均化和儲(chǔ)存。預(yù)均化好后石灰石帶式輸送機(jī)送入配料庫。

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.

為避免粉塵污染，破碎車間設(shè)有氣箱脈沖袋收塵器一臺，抽取破碎機(jī)及帶式輸送機(jī)下料處的含塵氣體，經(jīng)收塵器凈化后的氣體由排風(fēng)機(jī)排入大氣。

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、石膏及鐵粉、混合材輸送 Crushing of slag, gypsum; Conveying of iron powder and admixture

由汽車運(yùn)入廠區(qū)的粘土、石膏等生產(chǎn)輔助原料，分別卸入破碎站料倉內(nèi)，經(jīng)料倉下可調(diào)速的板式喂料機(jī)喂入破碎機(jī)進(jìn)行破碎，破碎后的物料由出料帶式輸送機(jī)轉(zhuǎn)運(yùn)至輔助原料堆場。

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.

鐵粉、混合材經(jīng)破碎系統(tǒng)輸送皮帶機(jī)送入輔助原料堆場。

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

配料站內(nèi)設(shè)一座φ8×14m圓倉儲(chǔ)存石灰石；另設(shè)置三座配料倉，儲(chǔ)存粘土、砂、鐵粉，儲(chǔ)量分別為360t和150t。參與配料的粘土、砂、鐵粉和石灰石分別由庫底調(diào)速鏈板機(jī)、電子皮帶秤按設(shè)定的配比卸出，經(jīng)帶式輸送機(jī)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?zé)晒夥治鰞x和微機(jī)組成的生料質(zhì)量控制系統(tǒng)，可自動(dòng)分析出磨生料成分，并根據(jù)分析結(jié)果和設(shè)定的目標(biāo)值自動(dòng)調(diào)節(jié)電子皮帶秤轉(zhuǎn)速以控制各原料的下料量，確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生料粉磨及廢氣處理Raw meal grinding and treatment of waste gas

來自庫底皮帶輸送機(jī)的配合原料，經(jīng)磨頭鎖風(fēng)裝置喂入HRM2800立磨粉磨，出磨成品由旋風(fēng)分離器收集經(jīng)鏈?zhǔn)捷斔蜋C(jī)、斗式提升機(jī)送至生料均化庫，磨尾廢氣至窯尾電收塵器凈化處理，然后排入大氣。磨機(jī)生產(chǎn)能力：當(dāng)產(chǎn)品細(xì)度為0.08方孔篩篩余≤12%，入磨物料粒度≤40mm。水分入磨時(shí)≤6 %，出磨時(shí)小于0.5%，臺時(shí)產(chǎn)量為130噸，入磨氣體溫度控制≤350℃，熱源利用廢氣。生料磨的年運(yùn)轉(zhuǎn)率為60.9%。烘干熱源來自窯尾高溫風(fēng)機(jī)排出的部分廢氣。

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窯、磨廢氣處理Treatment of waste gas of kiln and mill

窯尾預(yù)熱器的廢氣，經(jīng)高溫風(fēng)機(jī)排出，一部分送至原料粉磨作烘干熱源，其余部分經(jīng)增濕塔調(diào)質(zhì)后，與原料磨排出的廢氣匯合，進(jìn)入袋收塵器凈化，由排風(fēng)機(jī)排入大氣。當(dāng)原料磨停運(yùn)時(shí)，窯尾預(yù)熱器排出的廢氣則全部進(jìn)入增濕塔。廢氣處理系統(tǒng)收下的粉塵經(jīng)鏈運(yùn)機(jī)、提升機(jī)等輸送設(shè)備送入生料均化庫或生料稱重倉；當(dāng)增濕塔工作不正常，收下的窯灰水分過大時(shí)，增濕塔下面的螺旋輸送機(jī)反轉(zhuǎn)可將濕窯灰排出，再由人工用小車推走。

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.   

在系統(tǒng)布置上，窯、磨廢氣處理系統(tǒng)與生料磨和預(yù)熱器塔架呈環(huán)狀矩形布置，排廢氣的鋼煙囪依附在預(yù)熱器塔架上，不但布置緊湊、占地少，而且廢氣管道短，節(jié)省投資。

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

設(shè)置一座儲(chǔ)量為6500噸的φ15×50m多股流（MF）均化庫儲(chǔ)存、均化生料。從生料磨來的合格生料由提升機(jī)送至多股流(MF)生料均化庫頂，經(jīng)庫頂生料分配器分流后呈放射狀從庫頂多點(diǎn)下料，使庫內(nèi)料層幾乎呈水平狀分層堆放，出料則由庫底充氣系統(tǒng)分區(qū)供給松動(dòng)空氣，豎向取料后進(jìn)入庫底混合室。卸料時(shí)，向兩個(gè)相對的料區(qū)充氣，生料受氣力松動(dòng)并在重力作用下在各卸料點(diǎn)上方形成小漏斗流，生料在自上而下的流動(dòng)過程中進(jìn)行重力混合的同時(shí)，各卸料孔漏入卸料槽的生料從不同的半徑位置上向庫中心室流動(dòng)，在流動(dòng)過程中進(jìn)行著徑向混合，各卸料槽流入中心室的生料在充氣的作用下再獲得一次流態(tài)化混合，進(jìn)入庫底混合室后，在混合室內(nèi)進(jìn)一步充氣攪拌混合均化。出庫合格生料經(jīng)空氣輸送斜槽、斗式提升機(jī)送入設(shè)在庫頂?shù)纳�料喂料倉，出喂料倉的生料經(jīng)計(jì)量后，用斜槽和斗式提升機(jī)直接喂入預(yù)熱器系統(tǒng)。

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.

    均化所用高壓空氣由庫底羅茨風(fēng)機(jī)提供。

High pressure air for homogenizing is supplied by Roots blower under homogenizing silo.

 4.1.4.7窯尾預(yù)分解及熟料煅燒系統(tǒng)Kiln inlet pre-decomposition and clinker burning system

熟料煅燒采用φ3.5×54m回轉(zhuǎn)窯，窯尾設(shè)有單系列五級低壓損型旋風(fēng)預(yù)熱器和CDC型分解爐，熟料燒成熱耗850Kcal/kg.cl（3552.0KJ/kg），日產(chǎn)水泥熟料1500噸。

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%.

來自均化庫的合格生料計(jì)量后進(jìn)入預(yù)熱器，逐級預(yù)熱后進(jìn)入分解爐，分解后的生料再進(jìn)入回轉(zhuǎn)窯內(nèi)煅燒。分解爐所用的三次風(fēng)來自窯頭罩。

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.

為防止預(yù)熱器系統(tǒng)結(jié)皮堵塞，除在旋風(fēng)筒下設(shè)有膨脹倉外，還配有獨(dú)特的自動(dòng)控制噴吹系統(tǒng)以及必要的空氣炮，保證預(yù)熱器系統(tǒng)的正常運(yùn)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.

從回轉(zhuǎn)窯進(jìn)入篦冷機(jī)的高溫熟料，由篦板下鼓入的冷空氣急速冷卻，出篦冷機(jī)的熟料溫度為環(huán)境溫度+65℃，冷卻、破碎后的熟料由鏈斗輸送機(jī)送入熟料庫。

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.     

出篦冷機(jī)高溫廢氣一部分作為窯用二次空氣入窯；一部分由三次風(fēng)管送到分解爐作為燃燒空氣；剩余廢氣經(jīng)窯頭電收塵器凈化處理后排入大氣。電收塵器收下的粉塵經(jīng)鏈運(yùn)機(jī)送到熟料鏈斗機(jī)上入熟料庫。

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熟料儲(chǔ)存Clinker storage

出冷卻機(jī)的熟料由鏈斗輸送機(jī)送入兩座φ18×36m熟料庫中儲(chǔ)存。總儲(chǔ)量26000噸，儲(chǔ)存期17天。為方便熟料外運(yùn)，庫側(cè)設(shè)有熟料散裝系統(tǒng)。

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.

熟料由庫底計(jì)量設(shè)備卸出后，用帶式輸送機(jī)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

粉磨系統(tǒng)設(shè)一座石膏配料倉。配料倉由倉底微機(jī)配料秤按設(shè)定的比例搭配，熟料由庫底微機(jī)配料秤按設(shè)定的比例搭配后，由帶式輸送機(jī)送入水泥磨內(nèi)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.

水泥粉磨選用兩套由φ3.5×13m管磨機(jī)和N-1500型O-SEPA選粉機(jī)組成的閉路粉磨系統(tǒng)，臺時(shí)產(chǎn)量50t/h。出磨后的水泥用斗式提升機(jī)和空氣輸送斜槽送入O-SEPA選粉機(jī)中分選，粗粉返回磨內(nèi)再次粉磨；成品隨氣流進(jìn)入氣箱脈沖袋收塵器，被收集下來后由空氣輸送斜槽和斗式提升機(jī)送入水泥庫中儲(chǔ)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水泥儲(chǔ)存Cement storage

設(shè)4座φ15×41m帶減壓錐的水泥均化庫儲(chǔ)存出磨水泥，總儲(chǔ)量28000t，儲(chǔ)期15天。均化用氣由庫底羅茨風(fēng)機(jī)供給。

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水泥包裝及成品庫Cement packing and finished product storehouse

水泥包裝選用二臺八嘴回轉(zhuǎn)式包裝機(jī)，每臺包裝能力為100t/h。

Two 8-spout packers will be used for cement packing. Packing capacity is 100t/h per set.

來自水泥庫均化后的水泥由提升機(jī)送入振動(dòng)篩，篩去雜物后進(jìn)入衡壓倉，再進(jìn)入八嘴回轉(zhuǎn)式包裝機(jī)包裝成袋裝水泥，由帶式輸送機(jī)送至24×70m成品庫內(nèi)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. 

水泥包裝時(shí)，每袋重量由電子秤計(jì)量和調(diào)節(jié)。

Weight of bagged cement is weighed and adjusted by electric balance.

包裝系統(tǒng)設(shè)有完善的除塵設(shè)施，可保證廢氣達(dá)標(biāo)排放。

Good dust collecting system is set for cement packing to guarantee dust emission standard.

4.1.4.12 中央化驗(yàn)室 Central lab

廠區(qū)內(nèi)設(shè)一座中央化驗(yàn)室，負(fù)責(zé)進(jìn)出廠原料、燃料、半成品和成品的常規(guī)化學(xué)分析及物理檢驗(yàn)，以保證全廠各生產(chǎn)環(huán)節(jié)的產(chǎn)品質(zhì)量，對水泥產(chǎn)品質(zhì)量進(jìn)行調(diào)度、管理和監(jiān)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 工藝生產(chǎn)流程圖 Process flow sheet

    本工程生產(chǎn)工藝流程見圖。Refer to related drawing.

4.1.5 計(jì)量設(shè)施 Weighing facilities

為加強(qiáng)生產(chǎn)各個(gè)環(huán)節(jié)的管理，執(zhí)行相關(guān)計(jì)量法規(guī)，掌握各個(gè)工段生產(chǎn)狀況。本項(xiàng)目從原燃料進(jìn)廠到水泥成品出廠的各個(gè)工段設(shè)置了計(jì)量設(shè)施，并在機(jī)構(gòu)配置上設(shè)有專門計(jì)量管理人員，對計(jì)量設(shè)施進(jìn)行管理、維護(hù)，使工廠達(dá)到計(jì)量合格要求。具體配置見表。

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.

全廠物料計(jì)量設(shè)備表List of weighing equipment            

序號 No.	計(jì)量物料名稱 Material	計(jì)量設(shè)施安裝位置 Position	設(shè)施形式 Name of equipment	數(shù)量 Qty.	備 注 Remark
1	進(jìn)廠各原、燃料 Raw materials and fuel	進(jìn)廠門口 Entrance gate of the plant	汽車衡 Platform scale	1
2	入生料磨石灰石 Limestone to be fed to raw mill	配料庫庫底 Under material blending bin	調(diào)速配料秤 Speed-governable balance	1
3	入生料磨砂 sand to be fed to raw mill	配料庫庫底 Under material blending bin	調(diào)速配料秤 Speed-governable balance	1
4	入生料磨鐵粉 Iron powder to be fed to raw mill	配料庫庫底 Under material blending bin	調(diào)速配料秤 Speed-governable balance	1
5	入窯生料 Raw meal to be fed to kiln	窯尾喂料倉出口 Discharging point of weighing bin at kiln inlet	調(diào)速皮帶秤 Speed-governable balance	1
6	入水泥磨熟料 Clinker to be fed to cement mill	熟料庫庫底 Under clinker silo	調(diào)速配料秤 Speed-governable balance	4
7	入水泥磨石膏 Gypsum to be fed to cement mill	磨頭倉出口 Discharging point of feeding bin of mill	調(diào)速配料秤 Speed-governable balance	2
8	入水泥磨混合材 Admixture to be fed to cement mill	磨頭倉出口 Discharging point of feeding bin of mill	調(diào)速配料秤 Speed-governable balance	2
9	袋裝水泥 Bagged cement	包裝機(jī) Packer	電子秤 Electric balance	2

 

4.1.6 生產(chǎn)車間檢修設(shè)施Maintenance facilities

   （1）對于露天布置設(shè)備的檢修可由工廠自備一臺吊車，或從外面租借吊車解決。既節(jié)省了一些很少使用的檢修設(shè)備，又節(jié)約了土建、電氣投資。

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）對于受條件限制或無法露天但平時(shí)很少檢修的設(shè)備，如破碎機(jī)、風(fēng)機(jī)等，在其設(shè)備廠房的上方，設(shè)檢修吊鉤，以備檢修時(shí)臨時(shí)掛葫蘆使用。

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）對于檢修時(shí)頻繁使用起吊設(shè)備的地方，設(shè)置電動(dòng)葫蘆。如窯頭、窯尾起吊耐火磚；生料磨、水泥磨裝球等分別設(shè)有電動(dòng)葫蘆。

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 電氣及生產(chǎn)過程自動(dòng)化Electric and automation

4.2.1 電氣Electric

4.2.1.1 供電電源Power source

主電源由公共供電網(wǎng)供電，供電電源為 10 kV。

Power is mainly supplied by public power supply net. Voltage is 10 KV.

4.2.1.2 電壓等級Power voltage

配電電壓           10kV

Distribution voltage:10kV

低壓               0.4kV

Low voltage: 0.4kV

4.2.1.3 工程用電負(fù)荷及電耗 Powder demand

總裝機(jī)容量          14500kW

4.2.2 生產(chǎn)過程自動(dòng)化Processing automation

4.3.2.1 設(shè)計(jì)原則 Design principle

為滿足現(xiàn)代化水泥生產(chǎn)線的工藝要求，保證工藝設(shè)備可靠運(yùn)行，穩(wěn)定工藝參數(shù)，保證產(chǎn)品質(zhì)量，節(jié)約能源，提高生產(chǎn)線的運(yùn)轉(zhuǎn)率。本工程采用技術(shù)先進(jìn)，性能可靠，PLC計(jì)算機(jī)控制系統(tǒng)，對主生產(chǎn)線集中監(jiān)視、操作和分控制，可有效提高電控設(shè)備的可靠性和可維護(hù)性，實(shí)現(xiàn)控制、監(jiān)視、操作的現(xiàn)代化。對包裝車間，采用PLC現(xiàn)場控制站和現(xiàn)場操作站進(jìn)行控制、監(jiān)視和操作，其信號通過高速通信網(wǎng)與中控室操作站連接。通過中控室操作站與工廠管理計(jì)算機(jī)的網(wǎng)絡(luò)連接，使管理人員隨時(shí)掌握工廠的實(shí)際情況，實(shí)現(xiàn)管理現(xiàn)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 給水排水Water supply and drainage

4.3.1

 設(shè)計(jì)原則：貫徹節(jié)約用水、充分利用水資源，節(jié)約用地、節(jié)省投資的原則。

Design principle: saving water and earth, full use of water resource and saving investment

4.3.2 用水量 Water amount

   （1）全廠生產(chǎn)用水量       9654m3/d

        其中：循環(huán)用水量     8665m3/d

              生產(chǎn)直耗水量    787m3/d(其中:中水回用414m3/d)

              輔助生產(chǎn)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）循環(huán)回水量           8419m3/d

       Returned circulation water: 8419m3/d 

   （3）循環(huán)補(bǔ)充水量          246m3/d

       Supplement circulation water: 246m3/d

   （4）循環(huán)水利用率           97.1%

       Usage rate of circulation water: 97.1%

   （5）消防補(bǔ)充水量          180m3/d

       Supplement fire-fighting water: 180m3/d

   （6）廠區(qū)生活用水量         80m3/d

       Living water in the plant: 80m3/d

4.3.3 供水水壓pressure of supplied water

  水壓 Water pressure

生產(chǎn)用水水壓：車間管道進(jìn)口壓力采用0.25～0.35MPa，增濕塔回流式噴嘴進(jìn)口壓力采用3.3MPa。生活用水滿足用水點(diǎn)水壓要求。消防水壓：室外消火栓出口壓力不低于0.1MPa，室內(nèi)消火栓水壓滿足最不利點(diǎn)滅火要求。

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 供水系統(tǒng) Water supply system

   （1）生產(chǎn)循環(huán)供水系統(tǒng)Water supply system for production and circulation

為了充分利用水資源，節(jié)約用水，各車間生產(chǎn)設(shè)備冷卻水采用密閉式回流、余壓上塔循環(huán)冷卻系統(tǒng)。本方案可節(jié)省一組上塔熱水泵和熱水池，減少設(shè)備和構(gòu)筑物，且節(jié)約能源，減少用地，降低投資，循環(huán)水利用率高。經(jīng)冷卻塔（GBNL3-350型，Q＝350.0m3/h，N＝11kW，一座）冷卻后的水自流入循環(huán)給水池，再由循環(huán)泵（2G250WFB-FD型，Q=260.0m3/h，H=55.0m，N=90kW，三臺，兩用一備)加壓供給各生產(chǎn)車間設(shè)備冷卻用水點(diǎn)。循環(huán)過程中的損失水量由生產(chǎn)、生活管網(wǎng)補(bǔ)給。

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、消防供水系統(tǒng)Water supply system for fire fighting and living

本工程的車間生活用水、消防用水、輔助生產(chǎn)用水、窯頭篦冷機(jī)噴水、部分增濕塔噴水（另外部分由中水回用供給）由該系統(tǒng)供給。生活水池的水經(jīng)生活泵（2G80WFB-C型，Q=45m3/h，H=57m，N=22kW，二臺，一用一備）加壓后供給全廠使用。系統(tǒng)中設(shè)置了一座高位水池（V=500m3）以便水量調(diào)節(jié)，并儲(chǔ)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.

增濕塔、篦冷機(jī)用水另設(shè)加壓泵單獨(dú)加壓（增濕塔噴水加壓泵型號為DG25-50×9型，Q=25m3/h，H=450m，N=75kW，二臺，一用一備；窯頭篦冷機(jī)噴水加壓泵為D12-50×3型，Q=9m3/h，H=165m，N=15kW，二臺，一用一備）。

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 建筑結(jié)構(gòu)Building and structure

4.4.1 建筑Building

4.5.1.1 設(shè)計(jì)原則 Design principle

根據(jù)全廠平面布局，工藝生產(chǎn)流程以及生產(chǎn)設(shè)備確定建筑, 物的開間、跨度和空間。由于水泥廠生產(chǎn)車間各建筑物、構(gòu)筑物形式各不相同，所以將運(yùn)用, , 建筑手段來統(tǒng)一建筑形式，并遵守技術(shù)先進(jìn)、經(jīng)濟(jì)合理、安全適用、確保質(zhì)量的設(shè)計(jì)原則。

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.