Energy saving and emission reduction is an eternal topic, with the carbon peak, the concept of carbon neutralization, the implementation of the new cement unit energy consumption quota GB16780-2021, some areas require that by 2025, the energy consumption quota standard should reach the benchmark energy consumption level of less than 1 in more than 30% of enterprises, while electricity prices are also rising. Energy saving and consumption reduction is a real cost saving and efficiency improvement. At present, the power consumption of grinding process per ton of cement in most cement enterprises is between 26 and 32 degrees, some of the old design production lines are still above 34 degrees, while the newly built energy-saving production line has been able to achieve about 20 degrees, the gap between enterprises is large, there is a larger room for improvement, in addition to adding mineral powder to increase production, strengthen system operation and other traditional measures. The key power-saving measures for the cement grinding process (grinding station) are summarized as follows:
1. In terms of process equipment selection, the current power consumption is: roller press finish grinding process 2. Make good use of the roller press. At present, it is found that the roller presses of some enterprises are not well used and maintained, and the corresponding effects are not achieved, so it is necessary to ensure that the roller presses do work, the current of the roller presses can not be too low, the roller presses are regularly checked to ensure that the roller presses do work well, the feeding device of the roller presses can be transformed, the rollers are frequently overlaid or the column nail rollers are used, the extrusion effect is increased, the pressure of the ball mill is reduced, and the time is increased. And that pow consumption of the system is reduced. At present, there are two key points for the roller press: one is the feeding device and the distributing device to ensure the feeding stability and the extrusion effect; the other is the normal operation of the hydraulic electric control mechanism to ensure that the extrusion force meets the design requirements. 3. For the interior of the mill, in addition to the conventional adjustment of the steel ball gradation, attention should be paid to the conditions of the partition plate, the grinding grate plate and the activation ring. It is recommended to use a new type of anti-blocking lining plate to increase the ventilation and fine powder throughput in the mill; It is suggested to use a new type of ultra-thin lining plate to reduce the weight of the mill and save power consumption. According to theoretical calculation, if all the mills use ultra-thin lining plates and new partition plates, the power consumption per ton of cement can be reduced by more than 2 degrees. The ceramic ball grinding body is used, the ceramic ball grinding body technology is mature at present, and the power consumption of 2-4 degrees grinding can be reduced by using the ceramic ball in the second bin or the third bin in a system with a good matching roller press. In actual production, periodically or after the resistance increases, manually clean grate gap, and insist on reversing the warehouse once a year, pick up the broken and out-of-round steel balls, and adjust the gradation again. 4. Regularly carry out four-powder analysis, analyze and judge the powder separation efficiency of V separator and powder separator, and deal with abnormalities in time to ensure the fineness and specific surface area of the finished product of V separator to the mill; ensure the powder separation efficiency of the high efficiency powder separator of the mill, regularly check the two powder separators, and timely remove the dust accumulated at the horizontal section of the inlet of the high efficiency powder separator; At the same time, it is recommended to regularly analyze the particle size distribution of the cement out of the mill. If possible, an online laser particle size analyzer can be installed. 5. Large fans such as circulating fans and tail exhaust fans are technically transformed into energy-saving fans, and energy-saving speed regulation modes such as variable frequency speed regulation are implemented. Generally, the design and selection of production line equipment are too large, and there will be a large deviation between actual production and design. Fans may not run on the best performance curve. In addition, the efficiency of previous fans is not high. As a result, the overall operation efficiency is relatively low. At present, the efficiency of the newly designed fan is relatively high, reaching 82-85%. At present, the speed regulation modes include the traditional variable frequency speed regulation, magnetic couple speed regulation, rotor energy feedback speed regulation and other new speed regulation modes (the new technology is theoretically more energy-saving and simpler than high-voltage variable frequency). The new fan plus the energy-saving speed regulation mode can save a lot of electricity. 6. Use high-efficiency and energy-saving motor. There are many motors in cement plants, some of which were built earlier. At that time, the motor technology was limited and no high-efficiency and energy-saving motors were used. In recent years, the motor technology has developed rapidly. The former energy-saving and high-efficiency motors have now become ordinary motors. The latest YE4 motors and permanent magnet motors are the most energy-saving motors at present. After the large motors are replaced by energy-saving motors, the energy-saving effect is remarkable. In particular, the motor of the powder concentrator is directly replaced by a permanent magnet motor, the speed reducer can be cancelled, the three-level energy transmission from the motor, the speed reducer and the rotor equipment is reduced to the two-level energy transmission, the overall transmission efficiency is improved, the energy consumption is saved, the oil leakage points on the site are reduced, and the site is clean and tidy. 7. Use energy-saving air compressor to save electricity. Air compressor is a kind of equipment whose operation and maintenance cost is higher than equipment cost. In addition, the current sales situation is not good and the mill has more downtime. It is recommended to purchase a new energy-saving air-cooled air compressor that can meet the gas demand of packaging, bulk and unloading. It can be started when the mill is shut down and can stop the circulating water pump of the whole plant; It is suggested that the compressed air flow meter should be installed on the main pipeline of the air compression station, and the control of the leakage of compressed air should be strengthened in daily life to reduce the power consumption of the air compressor. The investment of this technical transformation is relatively small and the payback period is relatively short, especially when the original equipment needs to be replaced or the amount of maintenance is large, it is recommended to directly replace it with a new type of high-efficiency energy-saving air compressor for improved maintenance. 8. Use the energy-saving water pump. The water pump is mainly the circulating water pump of the system cooling water, the fire pump and other pumps with larger power. The technical transformation is the energy-saving water pump plus the energy-saving motor. The investment recovery period is short, and the investment can be recovered within two years. And 9, that transmission efficiency is improve, and electricity is saved. The traditional driving equipment such as large hoists and belt conveyors are generally driven by hydraulic couplers, which are inefficient and prone to failure. The new magnetic coupler has advantages over the hydraulic coupler in improving transmission efficiency, reducing vibration and adjusting installation accuracy. At present, the magnetic coupler is divided into a variety of structures, each of which has its own advantages and disadvantages, and you can choose according to the situation. Moreover, the unit price of the magnetic coupler is not high, and the magnetic coupler can be replaced in batches at one time or one by one according to the situation. 10. Reduce the resistance of the dust collector at the mill tail and reduce the power consumption of the system fan. It is suggested that the dust collection resistance of the grinding tail bag should be controlled within 1000 pa, preferably within 800 pa, and the tightness of the dust collector should be checked regularly, focusing on the manhole door, shell welds and other parts. In addition, attention should be paid to checking the air leakage at the ash discharge of the dust collector hopper, and the sealing should be strengthened by using the better quality dividing wheel or the leather curtain valve of the current new technology. Strengthen the daily inspection and maintenance to reduce the air leakage of the dust collector. 11. Reduce the power consumption wasted by belt, bucket lifting idling and low efficiency operation. In the last two years, with the strict control of environmental protection and overload management, the quality of many materials entering the cement plant is uneven, large materials, sundries, sticky and wet materials occur from time to time, the time of incoming materials is not very stable, and various emergencies increase, resulting in the belt and bucket lifting of incoming materials can not run well at full load, so it is necessary to control the quality and time of incoming materials from the management. Reduce the no-load and low-load running time of the belt and bucket elevator, and save the power consumption. 12. Electrical energy-saving transformation, such as the use of phase advancer, capacitor compensator and other energy-saving measures for the main motor and roller press motor. At present, there are energy-saving cases of using ceramic balls with variable frequency speed regulation for the main motor of the mill in China, which have also achieved good energy-saving results and are being promoted. 13. Strengthen management and control of incoming materials. Reduce the comprehensive moisture content of the materials entering the mill, and try to ensure that the comprehensive moisture content of the materials entering the mill is controlled below 1%, because the moisture content has a great impact on the mill time; For outsourcing, consider , good use of grinding AIDS to increase output and save electricity.". At present, the grinding AIDS with good performance can improve the unit time and the strength of cement at the same time. The liquid grinding aid with an excellent dosage of 0.3% can increase the machine-hour by more than 5%, increase the strength of clinker by 2-3 MPa in three days, and increase the strength of clinker by more than 5 MPa in 28 days (it can also reduce the dosage of clinker, and increase the machine-hour more). At present, there are many manufacturers of grinding AIDS, and the quality is mixed, and various factors are mixed among them, so it needs to be carefully identified and used. 15. Adopt intelligent operating system and build energy management center. The energy management center is a management tool, which will not save energy itself, but through data analysis and comparison, advanced benchmarking, it can find the energy waste points and gap points in the system, and ultimately achieve the goal of energy saving by adopting targeted improvement and optimization control of technical and management means. Compared with the traditional manual operation, the intelligent operating system is more accurate and more predictive, thus achieving the effect of optimal unit time and the lowest energy efficiency. The above measures can be measured and analyzed by each enterprise according to its own actual situation, and the project with small investment and short payback period can be implemented first; it is suggested that the equipment that needs to be replaced in the cycle should be directly replaced with the latest energy-saving equipment, and this improved maintenance method should be adopted; Through the implementation of the above measures, it is believed that the power consumption of most cement grinding processes can be reduced to below 29 degrees, and some enterprises can achieve the first-class standard below 26 degrees. In addition, photovoltaic power generation and new energy storage technology are developing day by day, the price is decreasing, many cement enterprises have built distributed photovoltaic power stations and energy storage power stations, the industry has also proposed zero-purchase power plants, photovoltaic power generation is the future trend, there are different preferential policies around the country. It is suggested that cement enterprises can choose the right time for construction according to local policies and the conditions of open space, roof, shed roof and other sites. At least, solar power generation on the top of car shed and office building can be built first, and new energy charging piles can be built for employees with energy storage technology to facilitate the charging of electric vehicles and new energy vehicles. The following lists the power consumption distribution data of typical enterprises with double closed-circuit process in cement preparation process. You can carry out targeted benchmarking transformation according to the situation of your own unit to reduce the power consumption of cement process. will be followed by a visit to the Eastern Hope < a href = "https://price.ccement.com/pricenewslist-1-500000-0.".
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