Tieling North Cement Co., Ltd.: Several Technical Transformations Work Together to Tackle the Problem of Reducing Coal Consumption

this year, Tieling North has actively implemented the green development strategy and achieved a historic breakthrough in coal consumption indicators through a series of technological transformations, which not only significantly enhanced the competitiveness of enterprises, but also set a practical benchmark for energy saving and carbon reduction of enterprises in regional industries. As the key equipment in cement production, the main function of the

grate cooler is to cool the high-temperature clinker and recover the heat for the combustion of the kiln system and the decomposition furnace. The original fixed grate plate of grate cooler in Tieling North has been used for a long time, and there are some defects in its structural design, resulting in low cooling efficiency and serious heat loss.

In order to solve this problem, Tieling North has upgraded the fixed grate plate of the grate cooler in an all-round way. The grate plate is made of a novel wear-resistant and high-temperature-resistant material, and the layout and the angle of the ventilation holes of the grate plate are optimized, so that the cold air can be more fully contacted with the high-temperature clinker, and the heat exchange efficiency is improved. After the transformation, the secondary air temperature of the grate cooler was increased by more than 50 ℃, and the tertiary air temperature was also significantly improved, which effectively reduced the consumption of raw coal in the kiln system. Air leakage control of the

system to reduce energy waste

Air leakage will not only lead to a decrease in the thermal efficiency of the system, but also increase the energy consumption of the fan, indirectly resulting in an increase in coal consumption. There are many air leakage points in the production system of northern Tieling, such as kiln head, kiln tail, pipeline connection and so on, which directly affect the economy of production.

In view of this situation, the company organized professional and technical personnel to conduct a comprehensive investigation of the entire production system, found out the leakage point, and formulated a detailed treatment plan. Fasten and seal the flanges and valves at the pipeline connections respectively, and repair or replace the damaged pipelines. After systematic treatment, the oxygen content of flue gas in northern Tieling was reduced to less than 5%, the air volume and speed in the system were more stable, the power consumption of fans was reduced by 10%, and the environmental protection cost and coal consumption of ammonia water were further reduced.

In the process of cement production, a large amount of return ash will be produced, which contains a certain calorific value, but in the past, most of it was directly discharged into the raw meal silo. Tieling North learned from the advanced experience of other enterprises, allocated a zipper machine from Siping North, carried out component analysis and calorific value detection of return ash, sent a proper amount of return ash and other raw materials into the kiln for calcination, and realized the reuse of calorific value return ash into the kiln. At present, the calorific value of ash returned to the kiln in the north of Tieling is stable at about 6 tons, and the coal consumption is obviously reduced.

Coal gangue

is a waste produced in the process of coal mining and washing, which has a certain calorific value and chemical composition. Tieling North innovatively mixes coal gangue as an ingredient into raw meal, which not only realizes the resource utilization of waste, but also reduces coal consumption. Through a large number of tests, the

quality control department has determined the appropriate proportion of coal gangue. The heat released in the process of coal gangue calcination can supplement part of the fuel demand and reduce the consumption of raw coal. At the same time, the alumina in the coal gangue can also improve the burnability of the raw meal and improve the quality of the clinker. At present, this item alone can reduce coal consumption by more than 2 kg in the north of Tieling.

In order to further reduce the dependence on raw coal, Tieling North actively explores the application of alternative fuels. After investigation and experiments, pyrolysis carbon black was successfully used as an alternative fuel for production.

Pyrolytic carbon black can partially replace raw coal for combustion. In the application process, the enterprise has carried out appropriate transformation of the adding method and adding point, which will not affect the quality of clinker on the premise of ensuring that the alternative fuel can be added in large quantities. At present, the physical coal consumption of Tieling North has been reduced by more than 10 kg by adding alternative fuels. At the same time, the application of alternative fuels also reduces the incineration of waste, and realizes the dual benefits of turning waste into treasure and energy saving and emission reduction.

Through the implementation of the above technical transformation measures, the comprehensive coal consumption of Tieling North in August has been reduced by more than 15% compared with that before the transformation, which can save about 15000 tons of standard coal per year and reduce about 37000 tons of carbon dioxide emissions, with remarkable economic and environmental benefits.

In the future, Tieling North will continue to increase investment in technological innovation, constantly explore more new ways and methods of energy saving and consumption reduction, and contribute more to the green and low-carbon development of the regional cement industry.

At present, the cement industry is facing the double test of energy saving, environmental protection and industrial intelligence upgrading. In order to implement the relevant policy requirements and accelerate the green low-carbon transformation and high-quality development of the cement industry, China Cement Network is scheduled for September 23-24. The 14th China Cement Energy Conservation and Environmental Protection Technology Exchange Conference and the 6th Intelligent Summit Forum were held in Zibo, Shandong Province. This conference will bring together industry experts, enterprise representatives and many industry stakeholders to gather group wisdom and promote energy-saving, environmental protection and intelligent transformation and upgrading of the cement industry.