Method and system for improving energy efficiency of ceramic spray drying tower

Abstract

The invention belongs to the technical field of energy efficiency metering, and particularly relates to a ceramic spray drying tower energy efficiency improving method and system. The method comprises the following steps: collecting fuel types and components of a ceramic spray drying tower and collecting an optimal drying curve of ceramic powder; obtaining thermal parameters of the ceramic spray drying tower; and based on the fuel types and components of the ceramic spray drying tower and the thermal parameters of the ceramic spray drying tower, cooperative matching of the air coefficient and the fuel flow of the combustion equipment is achieved by combining the optimal drying curve of the powder. Based on the fuel types and components of the ceramic spray drying tower and the thermal parameters of the ceramic spray drying tower, cooperative matching of the air coefficient and the fuel flow of the combustion equipment is achieved by combining the optimal drying curve of the powder, and therefore the drying temperature and the air volume are adjusted, and the purpose of improving the energy efficiency of the spray drying tower is achieved.

Description

Technical Field

[0001] The present invention belongs to the technical field of energy efficiency measurement, and particularly relates to a method and system for improving the energy efficiency of a ceramic spray drying tower. Background Art

[0002] In the entire process of ceramic production, the powder making process and the firing process consume the most energy. It is estimated that the powder making process consumes about 38% of the total energy consumption. It can be seen that the energy consumption problem of the spray drying tower is as important as that of the ceramic kiln. For the ceramic industry, the powder making process is generally carried out in a spray drying tower. Since the spray drying tower was introduced from abroad, it has developed very rapidly. In the past 30 years, its production capacity has increased from the initial 1000 kg / h and 1500 kg / h to the current 10000 kg / h and 14000 kg / h. The fuel types of the spray drying tower have also become more diverse, developing from liquefied petroleum gas and natural gas to diesel and heavy oil, and then to coal gas and water coal slurry.

[0003] As one of the core equipment of building ceramic enterprises, the energy cost of the spray drying tower has attracted more and more attention. Due to its large size and high sealing requirements, during the process of the spray drying tower from liquid material atomization to material fog drying and finally to the settlement of dried products, it is a black box for ceramic enterprises to control the internal situation. Workers' operation of the equipment often relies only on intuition and experience, resulting in the energy consumption problem of the spray drying tower being ignored.

[0004] The setting of the process parameters of the spray drying tower will directly affect the energy consumption and energy efficiency. However, due to the lack of energy consumption detection methods and scientific calculation and evaluation means for the relationship among them in enterprises, it often results in the situation that enterprises want to save energy but don't know how to do it. Many ceramic enterprises even know that the energy efficiency of the spray drying tower is unreasonable, but due to the lack of scientific guidance, they dare not take the risk of reducing the powder quality to adjust the process parameters. In addition, due to the large operation cycle of this drying equipment and high energy consumption per unit time, if there is no scientific method to guide energy conservation, energy waste will continue. Summary of the Invention

[0005] The purpose of the present invention is to overcome the above-mentioned deficiencies of the prior art, and provide a method and system for improving the energy efficiency of a ceramic spray drying tower to improve the thermal efficiency of the spray drying tower.

[0006] To achieve the above purpose, the technical solution of the present invention is:

[0007] In the first aspect, the present invention provides a method for improving the energy efficiency of a ceramic spray drying tower, including:

[0008] Collecting the fuel type and composition of the ceramic spray drying tower and collecting the optimal drying curve of the ceramic powder.

[0009] Obtain the thermal parameters of the ceramic spray drying tower;

[0010] Based on the fuel type and composition of the ceramic spray drying tower and the thermal parameters of the ceramic spray drying tower, combined with the optimal drying curve of the powder, to achieve the coordinated matching of the air coefficient and fuel flow of the combustion equipment.

[0011] Optionally, the achieving the coordinated matching of the air coefficient and fuel flow of the combustion equipment based on the fuel type and composition of the ceramic spray drying tower and the thermal parameters of the ceramic spray drying tower, combined with the optimal drying curve of the powder, includes:

[0012] Set the initial value of the air coefficient a, as well as the initial values of the powder moisture content and drying temperature;

[0013] Automatically adjust the combustion-supporting air flow based on the set initial value of the air coefficient a;

[0014] Automatically adjust the fuel flow based on the set initial values of the powder moisture content and drying temperature;

[0015] Calculate the value of the air coefficient a based on the volume percentage contents of oxygen, carbon monoxide, hydrogen, methane, carbon dioxide, and sulfur dioxide in the real-time flue gas collected;

[0016] Judge whether the calculated value of the air coefficient a meets the requirements. If not, adjust the combustion-supporting air flow according to the calculated value of a until it meets the requirements;

[0017] Based on the real-time drying temperature and powder moisture content collected, check whether the operation result reaches the temperature of the optimal drying curve of the powder, and perform corresponding fuel flow adjustment. Then, check again whether the value of the air coefficient a meets the requirements. If not, adjust the combustion-supporting air flow according to the value of a calculated from the real-time flue gas composition until the temperature and air volume of the optimal drying curve of the powder are satisfied.

[0018] Optionally, the thermal parameters of the ceramic spray drying tower include the fuel flow, temperature, combustion-supporting air flow, temperature, flue gas composition content, drying temperature, and powder moisture content.

[0019] Optionally, when the fuel is solid or liquid fuel, the value of the air coefficient a is calculated by the following method:

[0020]

[0021] In the formula:

[0022] —— are the volume fractions of the corresponding components in the flue gas respectively;

[0023] When the fuel is gaseous fuel, the value of the air coefficient a is calculated by the following method:

[0024]

[0025] Wherein:

[0026] —— The volume fraction of nitrogen gas in the gaseous fuel expressed as dry components.

[0027] Optionally, the flow rate of the combustion-supporting air is adjusted according to the calculated value of a as follows:

[0028]

[0029] Wherein:

[0030] U —— Fuel flow rate;

[0031] t0 —— Temperature of the combustion-supporting air;

[0032] t r —— Fuel temperature;

[0033] V a.d.th —— Theoretical air quantity for fuel combustion.

[0034] Optionally, when the fuel is a solid or liquid fuel, the theoretical air quantity V for fuel combustion a.d.th is calculated as follows:

[0035] V a.d.th = 0.0888ω Car + 0.0333ω S.ar + 0.2647ω H.ar – 0.0334ω O.ar

[0036] ω C.ar 、ω S.ar 、ω H.ar 、ω O.ar are the mass fractions of elements carbon, sulfur, hydrogen, and oxygen in the fuel respectively;

[0037] When the fuel is a gaseous fuel, the theoretical air quantity V for fuel combustion a.d.th is calculated as follows:

[0038]

[0039] are the volume fractions of CO, H2, H2S, C m H n 、O2、CO2 in the gaseous fuel expressed as wet components;

[0040] m, n are the numbers of carbon and hydrogen atoms in C m H n respectively.

[0041] Optionally, the determination of whether the value of a meets the requirements includes: when the fuel is solid, the value of a is between 1.40 and 1.60; when the fuel is liquid, the value of a is between 1.15 and 1.25; when the fuel is gas, the value of a is between 1.05 and 1.15.

[0042] In a second aspect, the present invention provides an energy efficiency improvement system for a ceramic spray drying tower, comprising:

[0043] An acquisition module, configured to acquire the fuel type and composition of the ceramic spray drying tower and to acquire the optimal drying curve of the ceramic powder.

[0044] A thermal parameter intelligent instrument module, configured to obtain the thermal parameters of the ceramic spray drying tower.

[0045] An air coefficient and fuel flow collaborative matching module, configured to achieve the collaborative matching of the air coefficient and fuel flow of the combustion equipment based on the fuel type and composition of the ceramic spray drying tower and the thermal parameters of the ceramic spray drying tower, in combination with the optimal drying curve of the powder.

[0046] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0047] Based on the fuel type and composition of the ceramic spray drying tower and the thermal parameters of the ceramic spray drying tower, the present invention combines the optimal drying curve of the powder to achieve the collaborative matching of the air coefficient and fuel flow of the combustion equipment, thereby realizing the adjustment of the drying temperature and air volume and achieving the purpose of improving the energy efficiency of the spray drying tower. Description of the Drawings

[0048] Figure 1 is the working principle diagram of the ceramic spray drying tower system;

[0049] Figure 2 is the flowchart of the method for improving the energy efficiency of the ceramic spray drying tower provided by the embodiment of the present application;

[0050] Figure 3 is the step flowchart for realizing the collaborative matching of the air coefficient and fuel flow of the combustion equipment;

[0051] Figure 4 is the composition schematic diagram of the energy efficiency improvement system for the ceramic spray drying tower provided by the embodiment of the present application;

[0052] Figure 5 is the composition schematic diagram of the air coefficient and fuel flow collaborative matching module. Detailed Embodiments

[0053] Embodiment:

[0054] The technical solution of the present invention will be further described below with reference to the drawings and embodiments.

[0055] Refer to Figure 1 As shown, it is the working principle diagram of the ceramic spray drying tower system, and the thermal efficiency of the spray drying tower is calculated according to formula (1).

[0056]

[0057] In the formula:

[0058] η r ——Thermal efficiency of the spray drying tower;

[0059] G——Mass flow rate of absolute dry powder;

[0060] Q yx ——Effective heat of the dried slurry;

[0061] Q gj ——Heat of fuel combustion;

[0062] The effective heat of the dried slurry is calculated according to formula (2):

[0063] Q yx =(X jl -X fl )×[4.1816×(100 - t)+2260+1.93×(125 - 100)]…………(2)

[0064] In the formula:

[0065] X jl ——Moisture content of the dry basis of the slurry, kg / kg

[0066] X fl ——Moisture content of the dry basis of the powder, kg / kg

[0067] t——Temperature of the powder, °C

[0068] 125——Final temperature of adsorbed water evaporation, °C.

[0069] It can be seen from formulas (1) and (2) that on the premise that the process parameters and the moisture contents of the slurry and the powder are determined, the method to improve the thermal efficiency of the spray drying tower is to reduce the input energy and increase the spray rate, so as to achieve the purpose of improving energy efficiency. Based on this, the method for improving the energy efficiency of the ceramic spray drying tower provided in this embodiment mainly includes the following steps:

[0070] 110, Collect the fuel type and composition of the ceramic spray drying tower and collect the optimal drying curve of the ceramic powder;

[0071] 120, Obtain the thermal parameters of the ceramic spray drying tower;

[0072] 130. Based on the fuel type and composition of the ceramic spray drying tower and the thermal parameters of the ceramic spray drying tower, in combination with the optimal drying curve of the powder, the air coefficient and fuel flow rate of the combustion equipment are coordinated and matched.

[0073] It can be seen from this that this method is based on the fuel type and composition of the ceramic spray drying tower and the thermal parameters of the ceramic spray drying tower, and combines the optimal drying curve of the powder to achieve the coordinated matching of the air coefficient and fuel flow rate of the combustion equipment, so as to realize the adjustment of the drying temperature and air volume, and achieve the purpose of improving the energy efficiency of the spray drying tower.

[0074] In a specific embodiment, the thermal parameters of the ceramic spray drying tower include the flow rate and temperature of the fuel, the flow rate and temperature of the combustion-supporting air, the content of flue gas components, the drying temperature, and the water content of the powder, which are monitored and obtained through intelligent instruments such as flow meters, thermometers, pressure gauges, and on-line moisture detectors installed on the ceramic spray drying tower system. The content of flue gas components includes oxygen, carbon monoxide, hydrogen, methane, carbon dioxide, sulfur dioxide, etc.

[0075] In a specific embodiment, step 130 includes:

[0076] 1301. Set the initial value of the air coefficient a, as well as the initial values of the powder moisture content and drying temperature;

[0077] 1302. Based on the set initial value of the air coefficient a, adjust the flow rate of the combustion-supporting air;

[0078] 1303. Based on the set initial values of the powder moisture content and drying temperature, adjust the flow rate of the fuel;

[0079] 1304. Calculate the value of the air coefficient a based on the volume percentage contents of oxygen, carbon monoxide, hydrogen, methane, carbon dioxide, and sulfur dioxide in the collected real-time flue gas components;

[0080] 1305. Determine whether the calculated value of the air coefficient a meets the requirements. If not, adjust the flow rate of the combustion-supporting air according to the calculated value of a until it meets the requirements.

[0081] Specifically, when the fuel is solid, the value of a between 1.40 and 1.60 meets the requirements; when the fuel is liquid, the value of a between 1.15 and 1.25 meets the requirements; when the fuel is gas, the value of a between 1.05 and 1.15 meets the requirements;

[0082] 1306. Based on the collected real-time drying temperature and the moisture content of the powder material, check whether the operating result reaches the temperature of the optimal drying curve of the powder material, and perform corresponding fuel flow regulation. Then, check again whether the value of the air coefficient a meets the requirements. If it does not meet the requirements, the combustion-supporting air flow should be adjusted according to the value of a calculated from the real-time flue gas composition until the temperature and air volume of the optimal drying curve of the powder material are satisfied:

[0083]

[0084] In the formula:

[0085] T —— Drying temperature.

[0086] When the combustible gases in the flue gas, such as carbon monoxide, hydrogen, methane, etc., tend to 0 and the oxygen content is small, and the value of a is close to the lower limit of the interval, it is an ideal actual combustion state. The drying temperature simultaneously meets the temperature of the optimal drying curve of the powder material, with the minimum heat energy loss and the maximum energy utilization rate, and the thermal efficiency of the spray drying tower can reach the maximum value.

[0087] In this way, through the above steps of operation, the method of accurately and efficiently coordinating the regulation of the air coefficient and fuel flow of the combustion equipment can be used to adjust the drying temperature and air volume, achieving the purpose of improving the energy efficiency of the spray drying tower.

[0088] In a specific embodiment, when the fuel is solid or liquid fuel, the value of the air coefficient a is calculated by the following method:

[0089]

[0090] In the formula:

[0091] —— The volume fractions of the corresponding components in the flue gas, respectively.

[0092] When the fuel is gas fuel, the value of the air coefficient a is calculated by the following method:

[0093]

[0094] In the formula:

[0095] —— The volume fraction of nitrogen gas in the gas fuel expressed in dry components.

[0096] Adjust the combustion-supporting air flow according to the value of the air coefficient a:

[0097]

[0098] In the formula:

[0099] U —— Fuel flow;

[0100] t0 —— The temperature of the combustion-supporting air;

[0101] t r —— The fuel temperature;

[0102] V a.d.th —— The theoretical air volume for fuel combustion.

[0103] When the fuel is solid or liquid fuel, the theoretical air volume V for fuel combustion a.d.th is calculated as follows:

[0104] V a.d.th = 0.0888ω Car + 0.0333ω S.ar + 0.2647ω H.ar - 0.0334ω O.ar

[0105] ω C.ar 、ω S.ar 、ω H.ar 、ω O.ar are the mass fractions of the elements carbon, sulfur, hydrogen, and oxygen in the fuel respectively.

[0106] When the fuel is gaseous fuel, the theoretical air volume V for fuel combustion a.d.th is calculated as follows:

[0107]

[0108] are the volume fractions of CO, H2, H2S, C m H n 、O2、CO2, expressed as wet components

[0109] m, n —— The number of carbon and hydrogen atoms in C m H n respectively.

[0110] Correspondingly, as Figure 4 shown, this embodiment also provides an energy efficiency improvement system 400 for a ceramic spray drying tower, including:

[0111] A collection module 401, configured to collect the fuel type and composition of the ceramic spray drying tower and to collect the optimal drying curve of the ceramic powder;

[0112] A thermal parameter intelligent instrument module 402, configured to obtain the thermal parameters of the ceramic spray drying tower;

[0113] The air coefficient and fuel flow collaborative matching module 403 is used to achieve the collaborative matching of the air coefficient and fuel flow of the combustion equipment based on the fuel type and composition of the ceramic spray drying tower and the thermal parameters of the ceramic spray drying tower, in combination with the optimal drying curve of the powder material.

[0114] Specifically, the air coefficient and fuel flow collaborative matching module 403 includes:

[0115] The setting unit 4031 is used to set the initial value of the air coefficient a, as well as the initial values of the moisture content and drying temperature of the powder material;

[0116] The primary combustion air flow regulating unit 4032 is used to regulate the combustion air flow based on the set initial value of the air coefficient a;

[0117] The primary fuel flow regulating unit 4033 is used to regulate the fuel flow based on the set initial values of the moisture content and drying temperature of the powder material;

[0118] The air coefficient a value calculation unit 4034 is used to calculate the air coefficient a value based on the volume percentage contents of oxygen, carbon monoxide, hydrogen, methane, carbon dioxide, and sulfur dioxide in the real-time flue gas collected;

[0119] The judgment and regulation unit 4035 is used to judge whether the calculated air coefficient a value meets the requirements. If not, it adjusts the combustion air flow according to the calculated a value until it meets the requirements;

[0120] The inspection and regulation unit 4036 is used to, based on the real-time drying temperature and powder material moisture content collected, check whether the operation result reaches the temperature of the optimal drying curve of the powder material, and perform corresponding fuel flow regulation. It also checks again whether the air coefficient a value meets the requirements. If not, it should adjust the combustion air flow according to the a value calculated from the real-time flue gas composition until the temperature and air volume of the optimal drying curve of the powder material are met.

[0121] Specifically, the adjustment of the combustion air flow according to the calculated a value is as follows:

[0122]

[0123] In the formula:

[0124] U —— fuel flow;

[0125] t0 —— combustion air temperature;

[0126] t r —— fuel temperature;

[0127] V a.d.th —— theoretical air volume for fuel combustion.

[0128] It should be noted that the energy efficiency improvement system of the ceramic spray drying tower provided by the embodiments of the present application can execute the energy efficiency improvement method of the ceramic spray drying tower provided by any embodiment of the present application, and has the corresponding functions and beneficial effects for executing the method.

[0129] The above embodiments are only for illustrating the technical concept and characteristics of the present invention, and the purpose is to enable those of ordinary skill in the art to understand the content of the present invention and implement it accordingly. It is not intended to limit the protection scope of the present invention. All equivalent changes or modifications made according to the essence of the content of the present invention should be covered within the protection scope of the present invention.

Claims

1. A method for improving the energy efficiency of a ceramic spray drying tower, characterized in that, Including: Collecting the fuel type and composition of the ceramic spray drying tower and collecting the optimal drying curve of the ceramic powder; Obtaining the thermal parameters of the ceramic spray drying tower; Based on the fuel type and composition of the ceramic spray drying tower and the thermal parameters of the ceramic spray drying tower, combined with the optimal drying curve of the powder, to achieve the coordinated matching of the air coefficient and fuel flow of the combustion equipment.

2. The method for improving the energy efficiency of the ceramic spray drying tower according to claim 1, characterized in that The achieving the coordinated matching of the air coefficient and fuel flow of the combustion equipment based on the fuel type and composition of the ceramic spray drying tower and the thermal parameters of the ceramic spray drying tower, combined with the optimal drying curve of the powder, includes: Setting the initial value of the air coefficient a and the initial values of the powder moisture content and drying temperature; Automatically adjusting the combustion-supporting air flow based on the set initial value of the air coefficient a; Automatically adjusting the fuel flow based on the set initial values of the powder moisture content and drying temperature; Calculating the value of the air coefficient a based on the volume percentage contents of oxygen, carbon monoxide, hydrogen, methane, carbon dioxide, and sulfur dioxide in the real-time flue gas components collected; Judging whether the calculated value of the air coefficient a meets the requirements. If not, adjusting the combustion-supporting air flow according to the calculated value of a until it meets the requirements; Based on the collected real-time drying temperature and powder moisture content, checking whether the operation result reaches the temperature of the optimal drying curve of the powder, and performing corresponding fuel flow adjustment. Then, checking again whether the value of the air coefficient a meets the requirements. If not, adjusting the combustion-supporting air flow according to the value of a calculated from the real-time flue gas components until the temperature and air volume of the optimal drying curve of the powder are satisfied.

3. The method for improving the energy efficiency of a ceramic spray drying tower according to claim 1, wherein, The thermal parameters of the ceramic spray drying tower include the fuel flow, temperature, combustion-supporting air flow, temperature, flue gas component content, drying temperature, and powder moisture content.

4. The method for improving the energy efficiency of the ceramic spray drying tower according to claim 2, wherein, When the fuel is solid or liquid fuel, the value of the air coefficient a is calculated by the following method: Where: —— the volume fractions of the respective components; When the fuel is gas fuel, the value of the air coefficient a is calculated by the following method: Where: —— The volume fraction of nitrogen gas in the gaseous fuel expressed as dry components.

5. The method for improving the energy efficiency of a ceramic spray drying tower according to claim 2 or 4, characterized in that, The adjusting the combustion-supporting air flow according to the calculated value of a is: Where: U - fuel flow; t0 - combustion-supporting air temperature; t r —— Fuel temperature; V a.d.th —— Theoretical air quantity for fuel combustion.

6. The method for improving the energy efficiency of the ceramic spray drying tower according to claim 5, wherein, When the fuel is solid or liquid fuel, the theoretical air volume V for fuel combustion a.d.th is calculated as follows: V a.d.th = 0.0888ω C，ar + 0.0333ω S，ar + 0.2647ω H，ar - 0.0334ω 0，ar ω C,ar 、 ω S,ar 、 ω H，ar 、 ω O.ar are the mass fractions of elemental carbon, sulfur, hydrogen, and oxygen in the fuel, respectively; When the fuel is gaseous fuel, the theoretical air volume V for fuel combustion a.d.th is calculated as follows: are respectively the volume fractions of CO, H2, H2S, C m H n , O2, CO2, expressed as wet components; m and n are the numbers of carbon and hydrogen atoms in C m H n respectively.

7. The method for improving the energy efficiency of the ceramic spray drying tower according to claim 2, wherein The judging whether the value of a meets the requirements includes: when the fuel is solid, the value of a is between 1.40 and 1.60; when the fuel is liquid, the value of a is between 1.15 and 1.25; when the fuel is gas, the value of a is between 1.05 and 1.

15.

8. An energy efficiency improvement system for a ceramic spray drying tower, characterized in that, Including: A collection module for collecting the fuel type and composition of the ceramic spray drying tower and for collecting the optimal drying curve of the ceramic powder; A thermal parameter intelligent instrument module for obtaining the thermal parameters of the ceramic spray drying tower; An air coefficient and fuel flow coordinated matching module for achieving the coordinated matching of the air coefficient and fuel flow of the combustion equipment based on the fuel type and composition of the ceramic spray drying tower and the thermal parameters of the ceramic spray drying tower, combined with the optimal drying curve of the powder.

9. The energy efficiency improvement system for a ceramic spray drying tower according to claim 8, wherein, The air coefficient and fuel flow coordinated matching module includes: A setting unit for setting the initial value of the air coefficient a and the initial values of the powder moisture content and drying temperature; A primary adjustment unit for combustion-supporting air flow for adjusting the combustion-supporting air flow based on the set initial value of the air coefficient a; The primary fuel flow regulation unit is used to regulate the fuel flow based on the set initial values of the moisture content of the powder material and the drying temperature; The air coefficient a value calculation unit is used to calculate the air coefficient a value based on the volume percentage contents of oxygen, carbon monoxide, hydrogen, methane, carbon dioxide, and sulfur dioxide in the real-time flue gas collected; The judgment and regulation unit is used to judge whether the calculated air coefficient a value meets the requirements. If it does not meet the requirements, the combustion-supporting air flow is regulated according to the calculated a value until it meets the requirements; The inspection and regulation unit is used to, based on the collected real-time drying temperature and the moisture content of the powder material, inspect whether the operation result reaches the temperature of the optimal drying curve of the powder material, and perform corresponding fuel flow regulation. Then, it checks again whether the air coefficient a value meets the requirements. If it does not meet the requirements, the combustion-supporting air flow should be regulated according to the a value calculated from the real-time flue gas composition until the temperature and air volume of the optimal drying curve of the powder material are met.

10. The energy efficiency improvement system of the ceramic spray drying tower according to claim 9, wherein, The regulation of the combustion-supporting air flow according to the calculated a value is as follows: In the formula: U - fuel flow; t0 - combustion-supporting air temperature; t r —— fuel temperature; V a.d.th —— Theoretical air quantity for fuel combustion.

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