新型干法回转窑热工计算

XXXX建材有限公司
新建2500t/d水泥熟料新型干法生产线及综合利用废渣生产130万吨/年水泥项目
熟料烧成系统热平衡计算书（预热器+分解炉+回转窑+篦冷机）
二〇一四年二月
一、基础数据
二、物料组分
二、计算
1、物料收入
（1）燃料消耗量：m r kg/kg−cl （2）生料消耗量：
①干生料理论消耗量（kg/kg-cl）：
m ysl=100−
α
100×A
f×m
r
100−L s
=
100−
100
100×24.5×m r
100−35.73
=1.556−0.381m r kg/kg−cl
②出预热器飞灰量：
m fℎ=0.144 kg/kg−cl
③烟囱飞损飞灰量：
m Fℎ＝m fℎ×(1−η)=0.144×(1−0.996)=0.001 kg/kg−cl ④入窑回灰量：
m yℎ=m fℎ−m Fℎ=0.143 kg/kg−cl
⑤考虑飞损后干生料实际消耗量：
m gs=m ysl+m Fℎ×100−L Fℎ100−L s
=1.556−0.381m r+0.001×100−34.4 100−35.73
=1.557−0.381m r kg/kg−cl ⑥考虑飞损后生料（含物理水）实际消耗量：
m s=m gs×
100
100−W s
=(1.557−0.381m r)×
100
100−0.2 =1.56−0.382m r kg/kg−cl
（4）空气消耗量
①理论空气用量
V lk=0.089C f+0.267H f−0.003(O f−S f)
=0.089×59.94+0.267×4.84+0.033×(0.84−7.91)
=6.394 N m3/kg−m
m lk=V lk×ρk=6.394×1.293=8.569 kg/kg−m
②窑头用实际干空气量
由于过剩空气系统αy＝1.05，窑头用燃料占47%，则窑头用实际干空气为：V yk=0.47×αy×V lk×m r=0.47×1.05×6.394×m r
=3.155m r N m3/kg−cl
m yk=3.155m r×1.293=4.079m r kg/kg−cl
其中：
一次空气：
V y1k=3.155m r×0.3=0.947m r N m3/kg−cl
m y1k=4.079m r×0.3=1.224m r kg/kg−cl
二次空气：
V y2k=3.155m r×0.65=2.051m r N m3/kg−cl
m y2k=4.079m r×0.65=2.651m r kg/kg−cl
窑头漏风：
V ylok=3.155m r×0.05=0.158m r N m3/kg−cl
m ylok=4.079m r×0.05=0.204m r kg/kg−cl
③分解炉实际用干空气量（出口过量空气系数1.15）
出分解炉过剩空气量：
V1=(αf−1)×V lk×m r
=(1.15−1)×6.394m r=0.959m r N m3/kg−cl
分解炉用燃料燃烧理论空气量：
V2=0.53×V lk×m r
=0.53×6.394m r=3.389m r N m3/kg−cl
窑尾废气中过剩空气量：
V3=(αy−1)×0.47×V lk×m r
=0.05×0.47×6.394m r=0.15m r N m3/kg−cl
分解炉及窑尾漏风量（包括进分解炉一次空气，占比0.05）：
V flok=αflok×0.53×V lk×m r
=0.05×0.53×6.394m r=0.169m r N m3/kg−cl
m flok=0.169m r×1.293=0.219 kg/kg−cl
分解炉从三次风管抽风量：
V f2k=0.959m r+3.389m r−0.15m r−0.169m r
=4.029m r N m3/kg−cl
m f2k=4.029m r×1.293=5.209m r kg/kg−cl ④旋风预热器系统漏风量（漏风占理论空气量比0.16）
V xlok=0.16×V lk×m r
=0.16×6.394×m r
=1.023 N m3/kg−cl
m xlok=1.023m r×1.293=1.323 kg/kg−cl ⑤喂料带入空气量（风料比19.8N m3/kg）：
V sk=m s+m yℎ
19.8
=1.56−0.382m r+0.143
19.8
=0.086−0.019m r N m3/kg−cl
m sk=(0.086−0.019m r)×1.293=0.111−0.025m r kg/kg−cl
⑥进入冷却机冷空气量：
V Lk=2.14 N m3/kg−cl
m Lk=2.14×1.293=2.767 kg/kg−cl 物料总收入：
m zs=m r+m s+m yℎ+m y1k+m ylok+m flok+m xlok+m sk+m Lk
=m r+1.56−0.382m r+0.143+0.204m r+1.224m r
+0.219m r+1.323m r+0.086−0.019m r+2.767
=4.581+3.563m r kg/kg−cl
2、物料支出
（1）出冷却机熟料量：
m cl=1 kg/kg−cl
（2）预热器出口飞灰量：
m fℎ=0.144 kg/kg−cl
（3）磨煤机抽冷却机空气量（2.396N m 3/kg −m ）
V mk =2.396m r N m 3/kg −cl
m mk =2.396m r ×1.293=3.098m r kg/kg −cl
（4）冷却机烟囱排出空气量：
V pk =V Lk −V y2k −V f2k −V mk =2.14−2.051m r −4.029m r −2.396m r
=2.14−8.476m r N m 3/kg −cl
m pk =(2.14−8.476m r )×1.293=2.767−10.959m r kg/kg −cl
（5）预热器出口废气量 ①生料中的物理水：W s =0.2%
m ws
=m s ×W s
100=(1.56−0.382m r )×0.2100
=0.003−0.001m r kg/kg −cl
V ws
=m ws 0.804
=0.004−0.001m r N m 3/kg −cl ②生料中的化合水
m ℎs =0.00353×m gs ×Al 2O 3f
=0.00353×(1.56−0.381m r )×2.75 =0.015−0.004m r kg/kg −cl
V ws =m ℎs
0.804
=0.019−0.005m r N m 3/kg −cl ③生料中分解的CO2： 生料中CO2的百分含量：
CO 2
s =CaO s
×4456+MgO s
×4440.3
=44.65×4456+0.48×44
40.3
=35.604%
m CO s
2=m gs ×CO 2s 100−m fℎ×L Fℎ
100
=(1.56−0.381m r )×35.604100−0.144×34.4
100
=0.555−0.136m r kg/kg −cl
V CO 2s =m CO s 2×22.444
=0.283−0.069m r N m 3/kg −cl ④燃料燃烧生成的理论烟气量：
V CO 2
r =22.412×C f 100
×m r =
22.412×59.94
100
×m r =1.119m r N m 3/kg −cl
V N 2
r =22.428×N f
100
×m r +0.79×V lk ×m r =22.428×0.97
100
×m r +0.79×6.394×m r =5.059m r N m 3/kg −cl
V H 2O r =22.42×H f 100×m r +22.418×W f
100
×m r
=22.42×4.84100×m r +22.42×0.63100
×m r =0.554m r N m 3/kg −cl
V S 2O r
=22.432×S f
100
×m r =
22.42×0.84
100
×m r =0.006m r N m 3/kg −cl
V r =V CO 2r +V N 2
r +V H 2O r +V S 2O r =6.783m r N m 3/kg −cl
m r =( m lk +1−
A ar
100
)×m r =(8.569+1−
24.5
100
)×m r =9.022m r kg/kg −cl ⑤烟气中过剩空气量：
V k =(1.15−1+0.16)×V lk ×m r =1.982m r N m 3/kg −cl
其中：
V N 2k
=0.79×V k ×m r =1.566m r N m 3/kg −cl V O 2
k =0.21×V k ×m r =0.416m r N m 3/kg −cl m N 2k
=2822.4×V N 2
k
=1.985m r kg/kg −cl m O
2
k =3222.4
×V O 2
k =0.594m r kg/kg −cl ⑥喂料用空气
V sk =0.086−0.019m r N m 3/kg −cl m sk =0.111−0.025m r kg/kg −cl
其中：
V N 2sk =0.79×V sk ×m r =0.068−0.015m r N m 3/kg −cl V O 2
sk =0.21×V sk ×m r =0.018−0.004m r N m 3/kg −cl m N 2sk
=2822.4×V N 2
sk
=0.085−0.019m r kg/kg −cl m O
2
sk =3222.4×V O 2
sk =0.026−0.006m r kg/kg −cl 废气总量：
V f =V CO 2+V N 2+V H 2O +V O 2+V SO 2
=(0.283−0.069m r +1.119m r )+(5.059m r +1.566m r +0.068−0.015m r )
+(0.004−0.001m r +0.019−0.005m r +0.554m r )+(0.416m r +0.018−0.004m r )+0.006m r =0.392+8.62m r N m 3/kg −cl m f =m CO 2+m N 2+m H 2O +m O 2+m SO 2
=m ws +m ℎs +m CO s 2
+m r +m N 2k +m O 2k
+m sk =0.003−0.001m r +0.015−0.004m r +0.555−0.136m r +9.022m r
+1.985m r +0.594m r +0.111−0.025m r =0.684+11.408m r kg/kg −cl
物料总支出：
m zc =m cl +m fℎ+m mk +m pk +m f
=1+0.144+3.098m r +2.767−10.959m r +0.684+11.408m r
=4.595+3.547m r
3、热量收入
（1）燃料燃烧热：
Q rR =23001m r kJ/kg −cl
（2）燃料带入显热：
Q r =m r ×c r ×t r =1.16×50×m r =58m r kJ/kg −cl
（3）生料带入显热：
Q s =(m gs ×c s +m ws ×c ws )×t s
=[(1.557−0.381m r )×0.878+(0.003−0.001m r )×4.182]×60=69−16.95m r kJ/kg −cl
（4）入窑回灰带入显热：
Q yℎ=m yℎ×c yℎ ×t yℎ=0.143×0.836×60=7.173 kJ/kg−cl （5）空气带入显热：
①窑头一次空气带入热量：
Q y1k=m y1k×c y1k ×t y1k=1.224m r×1.297×36
=57.151m r kJ/kg−cl
②进冷却机空气带入热量：
Q Lk=m Lk×c Lk ×t Lk=2.767×1.297×36=129.179 kJ/kg−cl
③喂料空气带入热量：
Q sk=m sk×c sk ×t sk=(0.111−0.025m r)×1.298×60
=8.645−1.947m r kJ/kg−cl
④窑头漏风带入热量：
Q ylok=m ylok×c ylok ×t ylok=0.204m r×1.297×36
=9.525m r kJ/kg−cl
⑤分解炉漏风带入热量：
Q flok=m flok×c flok ×t flok=0.219m r×1.297×36
=10.226m r kJ/kg−cl
⑥旋风预热器漏风带入：
Q xlok=m xlok×c xlok ×t xlok=1.323m r×1.297×36
=61.774m r kJ/kg−cl
热量总收入：
Q zs=Q rR+Q r+Q s+Q yℎ+Q y1k+Q Lk+Q sk+Q ylok+Q flok+Q xlok
=23001m r+58m r+69−16.95m r+7.173+57.151m r+129.197+8.645−1.947m r+9.525m r+10.226m r+61.774m r
=214.015+23178.779m r kJ/kg−cl
4、热量支出
（1）熟料形成热：
对于石灰石和粘土配料的生料，不考虑碱性影响时，形成热计算如下：
Q cl=17.21×Al2O3cl+27.13×MgO cl+32.03×CaO cl−21.44×SiO2cl −2.47Fe2O3cl
=17.21×5.41+27.13×0.77+32.03×67.53−21.44×22.46
−2.47×3.38=1787.09 kJ/kg−cl
（2）出冷却机熟料显热：
Q Lcl=m Lcl×c Lcl ×t Lcl=1×0.771×85=65.535 kJ/kg−cl （3）预热器出废气带走显热：
Q f=V f×c f×t f=(V CO
2×c CO
2
+V N
2
×c N
2
+V H
2O
×c H
2O
+V O
2
×c O
2
+
V SO
2×c SO
2
)×340=[(0.283−0.069m r+1.119m r)×1.899+(5.059m r+
1.566m r+0.068−0.015m r)×1.311+(0.004−0.001m r+0.019−
0.005m r+0.554m r)×1.552+(0.416m r+0.018−0.004m r)×1.356+ 0.006m r×0.768]×340=233.58+4106.18m r kJ/kg−cl
（4）预热器出口飞灰带走显热：
Q fℎ=m fℎ×c fℎ ×t fℎ=0.144×0.895×340=43.819 kJ/kg−cl （5）磨煤机抽冷却机空显热：
Q mk=V mk×c mk×t mk=2.396m r×1.02×240=586.54m r kJ/kg−cl （6）冷却机排出空气热量：
Q Lpk=V Lpk×c Lpk×t Lpk=(2.14−8.476m r)×1.027×200
=439.556−1740.97m r kJ/kg−cl
（7）系统表面散热损失热量：
Q B=230 kJ/kg−cl
（8）冷却水带走热量：
Q ls=170 kJ/kg−cl
热量总支出：
Q zc=Q cl+Q Lcl+Q f+Q fℎ+Q mk+Q Lpk+Q B+Q ls
=1787.09+65.535+233.58+4106.18m r+43.819
+586.54m r+439.556−1740.97m r+230+170
=2969.58+2951.75m r kJ/kg−cl
热量平衡：总收入=总支出
214.015+23178.779m r=2969.58+2951.75m r
解得：m r=0.13623182≈0.136
Q rR=23001m r=23001×0.136=3128.136 kJ/kg−cl
ηy=1787.09
3128.136
=57.13%
说明：数据差是由于计算过程中四舍五入导致。