水泥工艺工程师手册.doc

工艺工程师手册 目录1. 一般规定2. 破碎3. 均化与储存4. 干法烧成5.1 原料粉磨5.2 水泥粉磨6. 燃料制备7.1 水泥储存7.2 水泥包装及成品堆存8. 物料烘干9. 输送设计10.1压缩空气站1. 一般规定1.1. 主要设备年利用率1.2. 主要生产系统工作制度1.3 各种物料储存期1.4 各种物料的休止角及容重1.5 各种设备动荷重系数1.6 海拔高度与天气压力的关系1.7 各种气体的平均比热1.8 燃料的平均比热1.9 物料成分的平均比热1.10 熟料矿物成分的平均比热1.11 水在不同温度下的汽化热1.12 不同温差与不同风速的散热系数(一)1.13 不同温差与不同风速的散热系数(二) 1.1 主要设备年利用率(表1)主机设备名称年利用率干法回转窑82干法原料磨7080辊式磨7080水泥磨6575煤磨6075石灰石破碎机2050包装机201.2 主要生产系统工作制度(表2)系统名称每周工作天数(d)每天工作班制石灰石破碎5712石灰石预均化(堆料)5712石灰石预均化(取料)73原料粉磨73生料均化及入窑73煤粉制备73熟料烧成73熟料储存及输送73水泥粉磨73水泥储存73水泥包装及散装5713煤、石膏及辅助原料破碎5712压缩空气站73*班制按8小时倒班计.1.3 各种物料储存期(d) (表3)物料名称库内储存露天堆存共计湿料干料石灰质原料510010510粘土质原料1015031015铁质原料20302030煤51020302540生料2.53.52.53.5熟料714714石膏0320352035混合材01025025230水泥10161016注 :(1).表中物料储存期是按窑日产量为基准作平衡计算. (2).石灰质原料。粘土质原料若为外购或由国家铁路。水运进厂时可取上限. (3).物料采用矩形预均化堆场以两堆储存时，应以一堆计算储存期； 圆形预均化堆场应以料堆容积的三分之二计算储存期. (4).熟料外运时可取上限. (5).混合材应视其来源。运距及品种确定储存期. (6).水泥储存期应与熟料储存期统一考虑，并结合市场需求，交通运输条件定. (7).表中库内储存系指预均化堆场。圆库。联合储库。堆棚等储库的储存方式.1.4 各种物料的休止角及容重(表4) 各种物料的休止角和容重与物料的水分。粒度及性质有关， 确切的数据必须根据项目的资料定.下列数据仅供设计参考.物料名称容重(t/m3)休止角()机械输送气力输送堆场或储库进料装载放料自流石灰石25mm1.41.51.71.41.53745泥灰岩25mm1.251.254055粘土25mm1.41.61.4硫铁矿渣0.91.01.11.20.91.0铁矿石25mm2.12.42.137硫铁矿25mm1.92.21.93743干砂1.51.61.54245铝矾土25mm2.42.62.4高岭土25mm2.22.62.2火山灰0.81.20.938粉煤灰0.60.40.845白垩25mm1.82.71.8石英25mm1.51.5砂岩25mm1.41.437火山灰0.81.20.938石膏25mm1.41.61.440页岩25mm1.21.41.21.4熟料25mm1.31.41.52732白水泥熟料25mm0.70.72530原煤25mm0.70.80.80.93745高炉矿渣25mm0.60.80.60.83545煤粉0.50.40.6生料粗料1.00.8细粉0.70.90.60.81.11.23045水泥细粉(灰)1.21.01.41.253060细粉(白)1.00.81.21.03060粗料1.21.0粉煤灰0.60.70.60.8窑灰0.30.50.30.50.765物料名称容重(t/m3) 一般窑皮1.82.5辊压机料饼2.22.5普通高铝砖2.22.5普通粘土砖2.02.1铬镁砖2.83.0磷酸盐砖2.65磷酸盐耐磨砖2.70碱性砖 普通型高强型2.12.2白云石砖2.752.98耐碱隔热砖1.65刚玉质浇注料3.1耐碱浇注料2.22.3高强耐碱浇注料2.22.4高强浇注料高强隔热砖0.60.7硅酸钙板0.130.23水玻璃1.351.45重油0.920.94原油0.760.88柴油0.92煤油0.800.84汽油0.70.73渣油0.920.96注：物料容重指干燥物料，当物料含水时其容重计算如下：设水分为x%,干料容重为M1.5 机械设备动载荷系数水泥工业专业设备的荷载包括静荷载和动荷载或动载荷系数，应由供应专业设备的公司提供.由本院设计的专业设备则由设备设计单位提供.通用设备若制造厂不提供荷载资料，其动载荷系数可参考下表：设备名称动载荷系数适用范围颚式破碎机4圆锥破碎机3旋回破碎机3锤式破碎机34.5反击式破碎机34.5辊式破碎机2.5板式喂料机1.5垂直荷载1.2传动轴拉力振动喂料机1.2抽板式喂料机2.0圆盘喂料机1.2叶轮式喂料机1.2螺旋喂料机1.2带式喂料机1.2带式输送机1.2支腿及首尾轮的垂直荷载1.2拉紧装置及尾轮水平拉力3传动轴水平拉力螺旋输送机1.2链式输送机1.2垂直荷载2水平方向拉力斗式提升机1.3空气输送斜槽1.2倾斜斗式提升机1.5垂直荷载2头部传动轴拉力和拐弯处拉力仓式泵1.2螺旋泵2粗粉分离器1.2旋风分离器1.2多管除尘器1.2袋式除尘器1.2空气过滤器1.2储气罐1.2抓斗手动1.1起重机电中。轻级1.2动重级1.3减速电动机2电动机1000r/min2.5减速机功率75kW2.0功率75kW1.2活塞式空气压缩机5回转式空气压缩机参考用设备名称动载荷系数备注辊KHD垂直2.5宁波厂压水平2.5机Fuller3.0乌兰厂机械所2.5辊式磨Loesche垂直3.3MPS垂直4.31.6 海拔高度与大气压力的关系 (表6)海拔高度(m)大气压力(Pa)大气压力(mm汞柱)010132576010010012575120098925742300977257334009652572450095459716100089899674150084659635200079727598300070661530400062661470500055595417600049329370计算公式:P=101325(10.02257Hs)5.256式中:P-海拔高度为Hs m处的大气压力，PaHs-海拔高度,km1.7 各种气体的平均比热 kJ/m3(kcal/ m3)(表7)tCO2H2O空气CO空气中的N2O2H2SO2H2SCH4C2H2C2H4C2H6C3H401.606(0.384)1.489(0.356)1.296(0.310)1.296(0.310)1.296(0.310)1.305(0.312)1.280(0.306)1.736(0.415)1.464(0.350)1.539(0.368)1.869(0.447)1.869(0.447)2.196(0.525)3.065(0.733)1001.736(0.416)1.497(0.358)1.301(0.311)1.301(0.311)1.301(0.311)1.313(0.31401.292(0.309)1.919(0.435)1.510(0.361)1.614(0.386)2.045(0.489)2.104(0.503)2.501(0.598)3.530(0.844)2001.802(0.431)1.514(0.362)1.309(0.313)1.305(0.312)1.305(0.312)1,334(0.319)1.296(0.310)1.894(0.453)1.552(0.371)1.752(0.419)2.183(0.552)2.325(0.556)2.794(0.668)3.973(0.950)3001.878(0.449)1.878(0.449)1.535(0.367)1.317(0.315)1.313(0.314)1.355(0.324)1.301(0.311)1.961(0.469)1.598(0.382)1.886(0.451)2.288(0.547)2.530(0.605)3.074(0.735)4.395(1.051)4001.940(0.464)1.556(0.372)1.330(0.318)1.320(0.318)1.322(0.316)1.376(0.329)1.301(0.311)2.024(0.484)1.644(0.393)2.007(0.480)2.367(0.566)2.718(0.650)3.333(0.797)4.793(1.146)5002.007(0.480)1.581(0.276)1.342(0.321)1.342(0.321)1.334(0.319)1.397(0.334)1.305(0.312)2.074(0.496)1.681(0.402)2.129(0.509)2.438(0.583)2.890(0.691)3.576(0.855)5.444(1.230)6002.058(0.192)1.606(0.384)1.355(0.32401.355(0.324)1.347(0.322)1.414(0.338)1.309(0.313)2.116(0.506)1.719(0.411)2.246(0.537)2.505(0.599)3.049(0.729)3.801(0.90805.449(1.303)7002.104(0.503)1.631(0.390)1.372(0.328)1.372(0.328)1.355(0.324)1.434(0.343)1.313(0.314)2.154(0.515)1.756(0.420)2.354(0.563)2.572(0.615)3.187(0.762)4.011(0.959)5.763(1.378)8002.145(0.513)1.650(0.397)1.384(0.331)1.388(0.322)1.368(0.327)1.451(0.347)1.317(0.315)2.187(0.523)1.794(0.429)2.459(0.588)2.626(0.628)3.341(0.799)4.203(1.005)6.047(1.446)9002.183(0.552)1.685(0.403)1.397(0.334)1.401(0.335)1.384(0.331)1.464(0.350)1.322(0.316)2.216(0.530)1.828(0.437)2.551(0.610)2.681(0.641)3.446(0.824)4.374(1.046)6.298(1.506)10002.216(0.530)1.715(0.410)1.109(0.337)1.414(0.338)1.397(0.334)1.476(0.353)1.330(0.318)2.258(0.540)1.861(0.445)2.643(0.632)2.731(0.653)3.559(0.851)4.537(1.085)6.516(1.558)11002.233(0.534)1.748(0.418)1.422(0.340)1.426(0.341)1.405(0.336)1.489(0.356)1.334(0.319)2.279(0.545)12002.258(0.540)1.777(0.425)1.434(0.343)1.439(0.344)1.418(0.339)1.501(0.359)1.338(0.320)13002.292(0.548)1.802(0.431)1.443(0.343)1.451(0.347)1.430(0.342)1.510(0.361)1.347(0.322)14002.313(0.553)1.823(0.436)1.455(0.348)1.460(0.349)1.439(0.344)1.518(0.363)1.355(0.324)15002.334(0.558)1.848(0.442)1.464(0.350)1.468(0.351)1.447(0.346)1.531(0.366)1.363(0.326)1.8 燃料的平均比热 kJ/kg(kcal/kg)(表8) 挥发份 或容重煤的比热kJ/kg(kcal/kg)燃油的比热kJ/kg(kcal/kg)比热t煤的挥发份(%)油的容重(kg/l)1015202530350.80.91.000.953(0.228)0.987(0.236)1.025(0.245)1.058(0.253)1.096(0.262)1.129(0.270)1.882(0.450)1.756(0.420)1.673(0.400)100.956(0.231)0.999(0.239)1.037(0.248)1.075(0.257)1.112(0.266)1.146(0.274)1.899(0.454)1.773(0.424)1.690(0.404)200.979(0.234)1.016(0.243)1.054(0.252)1.092(0.261)1.125(0.269)1.163(0.278)1.915(0.458)1.790(0.428)1.706(0.408)300.991(0.237)1.033(0.247)1.071(0.256)1.108(0.265)1.142(0.273) 1.179(0.282)1.932(0.462)1.807(0.432)1.732(0.412)401.008(0.241)1.046(0.250)1.083(0.259)1.121(0.268)1.158(0.277)1.196(0.286)1.949(0.466)1.823(0.436)1.740(0.416)501.025(0.245)1.062(0.254)1.100(0.263)1.138(0.272)1.175(0.281)1.213(0.290)1.966(0.470)1.840(0.440)1.756(0.420)601.037(0.248)1.079(0.258)1.112(0.266)1.154(0.276)1.192(0.285)1.230(0.294)1.982(0.474)1.857(0.444)1.773(0.424)701.050(0.251)1.087(0.260)1.129(0.270)1.167(0.279)1.209(0.289)1.246(0.298)1.999(0.478)1.874(0.448)1.790(0.428)801.066(0.255)1.104(0.264)1.146(0.274)1.184(0.283)1.225(0.293)1.267(0.303)2.015(0.482)1.890(0.452)1.807(0.432)901.079(0.258)1.121(0.268)1.158(0.277)1.200(0.287)1.242(0.297)1.284(0.307)2.032(0.486)1.097(0.456)1.823(0.436)1001.092(0.251)1.133(0.271)1.175(0.281)1.217(0.291)1.259(0.301)1.301(0.311)2.049(0.490)1.924(0.460)1.840(0.440)1101.108(0.265)1.150(0.275)1.197(0.285)1.234(0.295)1.276(0.305)1.317(0.315)2.066(0.494)1.940(0.464)1.857(0.444)1201.121(0.268)1.163(0.278)1.209(0.289)1.250(0.299)1.288(0.308)1.334(0.319)2.083(0.498)1.957(0.468)_1.874(0.448)1301.138(0.272)1.179(0.282)1.225(0.293)1.267(0.303)1.305(0.312)1.351(0.323)2.099(0.502)1.974(0.472)1.890(0.452)1401.154(0.276)1.196(0.286)1.242(0.297)1.284(0.307)1.322(0.316)1.368(0.327)2.116(0.506)1.991(0.476)1.907(0.456)1501.167(0.279)1.209(0.289)1.255(0.300)1.296(0.310)1.338(0.320)1.384(0.331)2.133(0.510)2.007(0.480)1.924(0.460)1601.184(0.283)1.225(0.293)1.271(0.304)1.313(0.314)1.355(0.324)1.401(0.335)2.150(0.514)2.023(0.484)1.941(0.464)1701.196(0.286)1.242(0.297)1.284(0.307)1.330(0.318)1.372(0.328)1.418(0.339)2.150(0.514)2.023(0.484)1.941(0.464)1.9 物料成分的平均比热 kJ/kg(kcal/kg) (表9)温度生料熟料窑灰矿渣SiO2CaOCaCO3MgOMgCO3高岭土00.790(0.189)0.736(0.176)0.830(0.199)-200.844(0.202)0.736(0.176)0.830(0.199)-0.774(0.185)-0.850(0.203)-1000.899(0.215)0.782(0.187)0.836(0.200)0.890(0.213)0.799(0.191)0.786(0.188)0.874(0.209)0.979(0.234)1.075(0.257)0.991(0.237)2000.953(0.228)0.824(0.197)0.878(0.210)0.896(0.214)0.824(0.197)0.820(0.196)0.928(0.222)1.004(0.240)1.154(0.276)1.066(0.255)3001.003(0.240)0.861(0.206)0.920(0.220)0.903(0.216)0.920(0.220)0.841(0.201)0.979(0.234)1.029(0.246)1.217(0.291)1.121(0.268)4001.058(0.253)0.895(0.214)0.962(0.230)0.933(0.223)0.970(0.232)0.853(0.204)1.020(0.244)1.054(0.252)1.267(0.303)1.158(0.277)5001.083(0.259)0.916(0.219)1.004(0.240)0.945(0.226)1.025(0.245)0.861(0.206)1.050(0.251)1.079(0.258)1.313(0.314)1.181(0.283)6001.108(0.265)0.937(0.224)1.004(0.240)0.962(0.230)1.066(0.255)0.870(0.208)1.079(0.258)1.100(0.263)1.347(0.322)7001.133(0.271)0.953(0.228)1.046(0.250)0.991(0.237)1.083(0.259)0.878(0.210)1.096(0.262)1.121(0.268)1.368(0.327)8001.158(0.277)0.970(0.232)1.046(0.250)1.008(0.241)1.092(0.261)0.887(0.212)1.104(0.264)1.142(0.273)1.380(0.330)9001.183(0.283)0.979(0.234)1.050(0.251)1.016(0.243)1.100(0.263)0.891(0.213)1.112(0.266)1.158(0.277)10001.154(0.276)0.991(0.237)1.050(0.251)1.029(0.246)1.108(0.265)0.895(0.214)1.171(0.280)11001.124(0.269)1.008(0.241)1.060(0.253)1.046(0.250)1.112(0.266)0.899(0.215)12001.095(0.262)1.033(0.247)1.060(0.253)1.075(0.257)1.117(0.267)0.903(0.216)13001.062(0.247)1.058(0.253)1.158(0.277)1.129(0.270)0.907(0.217)14001.033(0.247)1.092(0.261)1.160(0.278)1.133(0.271)0.912(0.218)15001.033(0.247)1.121(0.268)1.160(0.278)1.138(0.272)0.916(0.219)续表 kJ/kg(kcal/kg)温度SiO2CaOCaCO3MgOMgCO3高岭土脱高岭矿渣6001.066(0.255)0.870(0.208)1.079(0.258)1.100(0.263)1.347(0.322)1.191.029(0.246)0.962(0.230)7001.083(0.259)0.878(0.210)1.096(0.262)1.121(0.268)1.368(0.327)1.191.046(0.250)0.991(0.237)8001.092(0.261)0.887(0.212)1.104(0.264)1.142(0.273)1.380(0.330)1.191.062(0.254)1.008(0.241)9001.100(0.263)0.891(0.213)1.112(0.266)1.158(0.277)1.401.191.079(0.261)1.016(0.243)10001.018(0.265)0.895(0.214)1.151.171(0.280)1.401.191.092(0.261)1.029(0.246)11001.112(0.266)0.889(0.215)1.151.181.401.191.108(0.265)1.046(0.250)12001.117(0.267)0.903(0.216)1.151.181.401.191.117(0.267)1.075(0.257)13001.129(0.270)0.907(0.217)1.151.181.401.191.121(0.268)1.158(0.277)14001.133(0.271)0.912(0.218)1.151.181.401.191.129(0.270)1.1615001.138(0.272)0.916(0.219)1.151.181.401.191.131.161.10 熟料矿物成分的平均比热 kJ/kg(kcal/kg) (表10)温度C3Sb -C2Sg -C2SC3AC5A3CAC2AS1000.790(0.189)0.853(0.204)2003000.866(0.207)0.866(0.207)0.887(0.212)0.907(0.217)0.928(0.222)0.920(0.220)4000.891(0.213)0.891(0.213)0.953(0.228)0.941(0.225)4500.903(0.216)0.903(0.216)0.966(0.231)0.949(0.227)5000.912(0.218)0.933(0.223)0.916(0.219)0.924(0.221)0.953(0.228)0.979(0.234)0.958(0.229)6000.933(0.223)0.949(0.227)0.933(0.223)0.974(0.233)0.995(0.238)0.974(0.233)6750.945(0.226)0.966(0.231)0.949(0.227)1.008(0.241)0.987(0.236)7000.949(0.227)0.974(0.233)0.945(0.226)0.983(0.235)1.012(0.242)0.991(0.237)8000.966(0.231)0.995(0.238)0.995(0.238)1.029(0.246)1.004(0.240)9000.979(0.234)1.012(0.242)0.958(0.229)1.004(0.240)1.046(0.250)1.016(0.243)10000.995(0.238)1.025(0.245)1.012(0.242)1.054(0.252)1.029(0.246)11001.008(0.241)1.041(0.249)0.970(0.232)1.020(0.244)1.066(0.255)1.041(0.249)12001.012(0.242)1.054(0.252)1.029(0.246)1.071(0.256)1.054(0.252)13001.020(0.244)1.062(0.254)0.983(0.235)1.037(0.248)1.079(0.258)1.071(0.256)14001.029(0.246)1.046(0.250)1.083(0.259)15001.037(0.248)1.11 水在不同温度下的汽化热 kJ/kg(kcal/kg) (表11)tqtqtqtq02497.5(597.2)402403.4(574.7)802305.5(551.3)1202198.5(525.7)52485.8(594.4)452391.3(571.8)852292.6(548.2)1252184.7(522.4)102474.1(591.6)502380.0(569.0)902279.6(545.1)1302170.0(518.9)152462.4(588.8)552367.4(566.1)952266.6(542.0)1352155.0(515.3)202450.7(586.0)602355.7(563.3)1002253.7(538.9)1402140.8(511.9)252438.9(583.2)652343.2(560.3)1052239.9(535.6)1452125.3(508.2)302427.2(580.4)702331.0(557.4)1102226.5(532.4)1502110.2(504.6)352415.1(577.5)752318.5(554.4)1152212.7(529.1)2001957.2(468)1.12不同温度与不同风速的散热系数(一)kJ/m2h(kcal/m2h)(表12)散热 风速系数a m/s温差D t()00.240.480.690.901.201.501.752.04045.16(10.8)50.60(12.1)56.03(13.4)61.47(14.7)66.92(16.0)75.69(18.1)84.47(20.2)93.25(22.3)102.03(24.4)5047.67(11.4)53.11(12.7)58.54(14.0)63.98(15.3)69.42(16.6)78.61(18.8)87.40(20.9)96.18(23.0)104.54(25.0)6050.18(12.0)56.03(13.4)61.47(14.7)66.91(16.0)71.92(17.2)81.42(19.4)89.90(21.5)98.69(23.6)107.47(25.7)7052.69(12.6)58.54(14.0)64.40(15.4)69.83(16.7)74.85(17.9)84.05(20.1)92.83(22.2)101.61(24.3)110.39(26.4)8054.78(13.1)61.05(14.6)66.91(16.0)72.34(17.3)77.36(18.5)86.56(20.7)95.34(22.8)104.12(24.9)112.90(27.0)9057.29(13.7)63.56(15.2)69.42(16.6)74.85(17.9)79.87(19.1)89.07(21.3)97.85(23.4)106.63(25.5)115.83(27.7)10059.8(14.3)66.07(15.8)72.34(17.3)77.78(18.6)82.80(19.8)92.00(22.0)100.78(24.1)109.56(26.2)118.34(28.3)11062.31(14.9)68.58(16.4)74.85(17.9)80.29(19.2)85.31(20.4)94.50(22.6)103.29(24.7)112.07(26.8)120.85(28.9)12064.82(15.5)71.09(17.0)77.36(18.5)82.80(19.8)88.23(21.1)97.43(23.3)106.21(25.4)114.99(27.5)123.30(29.5)13067.32(16.1)74.01(17.7)80.29(19.2)85.72(20.6)90.74(21.7)99.94(23.9)109.14(26.1)117.50(28.1)124.19(29.7)14070.25(16.8)76.52(18.3)82.80(19.8)88.23(21.1)93.25(22.3)102.45(24.5)111.23(26.6)120.01(28.7)124.61(29.8)15072.34(17.3)79.03(18.9)85.72(20.5)91.16(21.8)96.18(23.0)105.38