Method for accounting yield of cement kiln and raw mill

Abstract

The invention discloses a method for accounting the yield of a cement kiln and a raw mill. The method comprises the following steps: S1, a remote transmission module for collecting the motor power of a bucket elevator; s2, power data of the bucket elevator during no-load or material stopping are collected; s3, collecting power data during stable production of the bucket elevator; s4, stabilizing the power consumed in the material digging process of the tail part during production; s5, the data obtained in the S2 and the S3 are processed through a mathematical method, and the lifting power of the raw material entering the kiln is obtained in combination with the power consumed in the tail material digging process during stable production; s6, calculating the corresponding kiln entering raw material amount or raw material grinding machine hour yield during stable operation; step S7, calculating theoretical material consumption K1; s8, the amount Q1 of the raw materials escaping from the uppermost-stage cyclone C1 is obtained; and step S9, calculating a real-time clinker yield value. According to the method, the yield of the raw material grinding system and the clinker yield of the sintering system can be simply and quickly calculated.

Description

Technical Field

[0001] This invention application belongs to the field of intelligent cement industry, specifically involving a method for calculating the output of cement kilns and raw material mills. Background Technology

[0002] The output per unit of a cement kiln is crucial for both cement plants and researchers. Currently, the cement industry faces the challenge of accurately determining clinker production. A common phenomenon in the industry is that most cement plants do not calculate clinker production based on the raw material feed rate of the raw material scale. There are many reasons for this, including fluctuations in scale measurement leading to significant errors, or the scales requiring periodic calibration that cement plants fail to perform on time. Some cement plants use the current of the inlet elevator to preliminarily estimate kiln output, but this method is too crude and has significant errors. First, the elevator current cannot directly determine the raw material feed rate. Second, inlet elevators vary considerably between different plants, involving differences in elevator height (e.g., 5-stage, 6-stage, 7-stage preheaters, etc.). Even with the same number of preheater stages, the type of bucket elevator for inlet can differ (e.g., belt conveyor or chain conveyor). Therefore, the output cannot be simply assessed using the elevator current. The common method used in cement plants to calculate kiln output is "inventory inventory." This method involves calculating the coefficient relationship between raw material scales and clinker based on long-term external sales (from truck scales). After determining the coefficient, the real-time output of the kiln system is obtained from the raw material scale readings. Aside from the error issues associated with inventory inventory, this method is very time-consuming, typically calculated monthly or quarterly. Inventory inventory is an internal accounting method suitable for managing clinker sales records, but not suitable for external use, and inconvenient for cement technicians or government regulatory agencies. As a professional intelligent cement company, finding a more accurate method for determining cement kiln output is particularly important. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention discloses a method for calculating the amount of material lifted during stable operation of the kiln feed elevator by monitoring its power during both no-load and stable operation, using a specific algorithm, and then applying the energy conservation formula. Furthermore, by using the dust content at the preheater outlet and the theoretical material consumption, the output of the cement kiln system can be calculated. Based on the same method, the hourly output of the raw meal mill system in a cement production line during stable operation can be theoretically calculated. This method requires computer control and data processing, all of which can be completed within an intelligent program, making it a simple and convenient calculation method.

[0004] The technical solution of the present invention is a method for calculating the output of cement kilns and raw material mills, comprising the following steps:

[0005] Step S1: Collect the remote transmission module of the bucket elevator motor power;

[0006] Step S2: Collect power data of the bucket elevator when it is unloaded or stopped;

[0007] Step S3: Collect power data of the bucket elevator during stable production;

[0008] Step S4: Power consumed during the tail-end material retrieval process in stable production;

[0009] Step S5: Process the data obtained in steps S2 and S3 using mathematical methods, and combine the power consumed in the tail material digging process during stable production to obtain the lifting power of the raw material entering the kiln;

[0010] Step S6: Calculate the amount of raw material fed into the kiln or the hourly output of the raw material grinding table corresponding to stable operation;

[0011] Step S7: Calculate the theoretical material consumption K1;

[0012] Step S8: Obtain the amount of raw material Q1 that escaped from the top-level cyclone C1;

[0013] Step S9: Calculate the real-time clinker production value.

[0014] Furthermore, the bucket elevator is either a kiln-feeding bucket elevator or a raw material homogenization silo-feeding bucket elevator.

[0015] Furthermore, the mathematical method described in step S5 is either the arithmetic mean or the trimmed mean. When the collected data is relatively stable and does not change much, the arithmetic mean is selected. When the collected data has obvious outliers, the trimmed mean is selected.

[0016] Furthermore, in step S5, the lifting power of the raw material entering the kiln is W2-W1-W3, where W1 is the power data when the bucket elevator is unloaded or stopped; W2 is the power data when the bucket elevator is in stable production; and W3 is the power consumed in the process of digging material at the tail end during stable production.

[0017] Furthermore, the formula for calculating the amount of raw material fed into the kiln during stable operation in step S6 is as follows: ;

[0018] Where: W1—Power of the hoist during no-load operation;

[0019] W2—Power of the elevator during stable production of the kiln system;

[0020] W3—Power consumed during the material scooping process at the tail end when the kiln system is in stable production;

[0021] η—Transmission efficiency, its value is related to the bucket elevator and motor, and is typically 0.9;

[0022] H – Lifting height;

[0023] Q – Raw material conveying capacity;

[0024] The formula for calculating the hourly output of a raw material grinding table is:

[0025] ;

[0026] Where: W1*——Power of the hoist during no-load operation;

[0027] W2*—Power of the elevator during stable production of the raw material mill;

[0028] W3*—Power consumed during the tail-end material extraction process when the raw material mill is in stable production;

[0029] η* — Transmission efficiency, its value is related to the bucket elevator and motor, and is typically 0.9;

[0030] H* — Increase height;

[0031] Q*——Raw material conveying capacity.

[0032] Furthermore, the formula for calculating the theoretical material consumption K1 in step S7 is as follows: ;

[0033] Where: A—the proportion of ash generated during fuel combustion incorporated into the raw meal during the production process;

[0034] L – The percentage of moisture and volatile substances lost by the raw meal during calcination.

[0035] Furthermore, the amount of raw material Q1 escaping from C1 in step S8 can be obtained by the following methods: obtaining the dust content and air volume data at the outlet of C1 through calibration, and then calculating Q1; when the power or current of the elevator is the same under the two working conditions of no kiln ash entering the kiln and kiln ash entering the kiln, the difference in the amount of raw material fed is the amount of kiln ash; under the condition of being equipped with a kiln ash silo with weighing, Q1 can be obtained directly through the program.

[0036] Furthermore, the formula for calculating the real-time clinker production value in step S9 is as follows: In the formula, Q is the amount of raw meal entering the kiln, Q1 is the amount of raw meal escaping, and K1 is the theoretical material consumption. When conveniently calculating the output of the kiln system, the ratio of raw meal to clinker entering the kiln is taken as a fixed value K1. The formula for the clinker output value is: .

[0037] The above method can quickly and easily calculate the output of the raw material mill system and the clinker output of the calcination system. It is applicable to cement plants, cement technicians, and government regulatory agencies, and is especially suitable for use in intelligent production lines due to its high calculation efficiency. It provides theoretical guidance for evaluating mill output and kiln system output, solving practical problems. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the present invention.

[0039] Figure 2 A comparison chart showing the power consumed during the tail-end material extraction process to ensure stable production.

[0040] In the diagram: 1. Kiln feed elevator; 2. Device for real-time monitoring of the operating power of the kiln feed bucket elevator with remote transmission function; 3. Preheater system; 4. Material from the raw material mill; 5. Raw material homogenization silo elevator; 6. Device for real-time monitoring of the operating power of the raw material homogenization silo bucket elevator with remote transmission function; 7. Raw material homogenization silo; 8. Computer control backend. Detailed Implementation

[0041] The specific embodiments of the present invention will now be described with reference to the accompanying drawings.

[0042] I. Evaluation Methods for Kiln System Output

[0043] like Figure 1 As shown, the old production line needs to add a remote transmission module for the power of the bucket elevator motor in the kiln, while the new production line can be designed directly to monitor the operating power of the bucket elevator in the kiln in real time.

[0044] Collect power data W1 of the bucket elevator when it is unloaded or stopped;

[0045] Collect power data W2 from the bucket elevator in the kiln during stable production.

[0046] The power W3 consumed during the material extraction process at the tail end during stable production can be determined by referring to... Figure 2 ;

[0047] We process W1 and W2 using mathematical methods to obtain (W2 - W1), which represents the lifting power of the raw material entering the kiln.

[0048] The amount of raw material fed into the kiln during stable operation was calculated using theoretical formulas.

[0049]

[0050] Where: W1—Power of the hoist during no-load operation, kW;

[0051] W2—Power of the elevator during stable production of the kiln system, kW;

[0052] W3—Power consumed during the material extraction process at the tail end of the kiln system during stable production, kW;

[0053] η—Transmission efficiency, its value is related to the bucket elevator and motor, and can be taken as 0.9;

[0054] H – Lifting height, in meters;

[0055] Q – Raw material conveying capacity, t / h

[0056] By retrieving the batching scheme from cement production, which remains unchanged during normal operation, the theoretical material consumption K1 can be calculated. It should be noted that, generally, the theoretical material consumption of clinker varies very little, typically taking a value of 1.53.

[0057] The dust content and air volume data at the outlet of C1 (the uppermost cyclone separator) are obtained through calibration. The amount of raw material escaping from C1, Q1 (unit: t / h), is calculated. Alternatively, Q1 can be obtained directly through a program if a kiln ash silo with weighing capabilities is installed.

[0058] Clinker production:

[0059] Using the above method, the clinker production value can be obtained in real time through the program.

[0060] II. Evaluation Methods for Raw Meal Mill Output

[0061] The old production line needs to add a remote transmission module for the motor power of the bucket elevator into the raw material silo. The new production line can be designed directly to monitor the operating power of the bucket elevator into the raw material silo in real time.

[0062] Collect power data (W1*) of the bucket elevator when the raw material homogenization silo is unloaded or stopped.

[0063] Collect the power data (W2*) of the bucket elevator in the raw material homogenization silo during stable production.

[0064] We process W1* and W2* using mathematical methods to obtain (W2* - W1*), which represents the improvement in efficiency of the raw material entering the raw material warehouse.

[0065] The power consumed (W3) during the material extraction process at the tail end during stable production can be referenced. Figure 2 ;

[0066] The amount of raw material entering the warehouse during stable operation is calculated using theoretical formulas, which is the hourly output of the raw material grinding table:

[0067]

[0068] Where: W1*——Power of the hoist during no-load operation, kW;

[0069] W2*——Power of the elevator during stable production of the raw material mill, kW;

[0070] W3*—Power consumed in the tail-end material scooping process during stable production of the raw material mill, in kW;

[0071] η* — Transmission efficiency, the value of which is related to the bucket elevator and motor, and can be 0.9.

[0072] H* — Lifting height, in meters.

[0073] Q*——Raw material conveying capacity, t / h (i.e., raw material grinding table output per hour)

[0074] III. A convenient method for government regulatory departments to calculate the output of kiln systems

[0075] The old production line needs to add a remote transmission module for the power of the bucket elevator motor in the kiln, while the new production line can be designed directly to monitor the operating power of the bucket elevator in the kiln.

[0076] Collect power data W1 of the bucket elevator when it is unloaded or stopped;

[0077] Collect power data W2 from the bucket elevator in the kiln during stable production.

[0078] The power W3 consumed during the tail-end material extraction process in stable production can be determined by referring to... Figure 2 ;

[0079] By processing W1 and W2 using mathematical methods, we obtain (W2 - W1 - W3), which represents the lifting power of the raw material entering the kiln.

[0080] The amount of raw material fed into the kiln during stable operation was calculated using theoretical formulas.

[0081]

[0082] Where: W1—Power of the hoist during no-load operation, kW;

[0083] W2—Power of the elevator during stable production of the kiln system, kW;

[0084] W3—Power consumed during the material scooping process at the tail end of the kiln system during stable production, in kW;

[0085] η—Transmission efficiency, its value is related to the bucket elevator and motor, and can be taken as 0.9;

[0086] H – Lifting height, in meters;

[0087] Q – Raw material conveying capacity, t / h

[0088] The ratio of raw meal to clinker entering the kiln can be taken as a fixed value K1, and the calculated clinker data can meet the requirements;

[0089] Clinker production:

[0090] Using the above method, the clinker production value can be obtained in real time through the program.

[0091] The above method allows for a simple and quick calculation of the output of the raw material mill system and the clinker output of the calcination system. It is particularly suitable for use in intelligent production lines. Furthermore, it provides theoretical guidance for evaluating mill output and kiln system output, solving practical problems.

Claims

1. A method for calculating the output of cement kilns and raw material mills, characterized in that, Includes the following steps: Step S1: Collect the remote transmission module of the bucket elevator motor power; Step S2: Collect power data of the bucket elevator when it is unloaded or stopped; Step S3: Collect power data of the bucket elevator during stable production; Step S4: Power consumed during the tail-end material retrieval process in stable production; Step S5: Process the data obtained in steps S2 and S3 using mathematical methods, and combine the power consumed in the tail material digging process during stable production to obtain the lifting power of the raw material entering the kiln; Step S6: Calculate the amount of raw material fed into the kiln or the hourly output of the raw material grinding table corresponding to stable operation; Step S7: Calculate the theoretical material consumption K1; Step S8: Obtain the amount of raw material Q1 that escaped from the top-level cyclone C1; Step S9: Calculate the real-time clinker production value.

2. The method for calculating the output of cement kilns and raw material mills according to claim 1, characterized in that, The bucket elevator is either a kiln-feeding bucket elevator or a raw material homogenization silo-feeding bucket elevator.

3. The method for calculating the output of cement kilns and raw material mills according to claim 1, characterized in that, The mathematical method described in step S5 is either the arithmetic mean or the trimmed mean. When the collected data is relatively stable and does not change much, the arithmetic mean is selected. When the collected data has obvious outliers, the trimmed mean is selected.

4. The method for calculating the output of cement kilns and raw material mills according to claim 1, characterized in that, In step S5, the lifting power of the raw material entering the kiln is W2-W1-W3, where W1 is the power data when the bucket elevator is unloaded or stopped; W2 is the power data when the bucket elevator is in stable production; and W3 is the power consumed in the process of digging material at the tail end during stable production.

5. The method for calculating the output of cement kilns and raw material mills according to claim 1, characterized in that, The formula for calculating the amount of raw material fed into the kiln during stable operation in step S6 is as follows: ; Where: W1—Power of the hoist during no-load operation; W2—Power of the elevator during stable production of the kiln system; W3—Power consumed during the material scooping process at the tail end when the kiln system is in stable production; η—Transmission efficiency, with a value of 0.9; H – Lifting height; Q – Raw material conveying capacity; The formula for calculating the hourly output of a raw material grinding table is: ； Where: W1*——Power of the hoist during no-load operation; W2*—Power of the elevator during stable production of the raw material mill; W3*—Power consumed during the tail-end material extraction process when the raw material mill is in stable production; η* — Transmission efficiency, valued at 0.9; H* — Increase height; Q*——Raw material conveying capacity.

6. The method for calculating the output of cement kilns and raw material mills according to claim 1, characterized in that, The formula for calculating the theoretical material consumption K1 in step S7 is: ; Where: A—the proportion of ash generated during fuel combustion incorporated into the raw meal during the production process; L – The percentage of moisture and volatile substances lost by the raw meal during calcination.

7. The method for calculating the output of cement kilns and raw material mills according to claim 1, characterized in that, The amount of raw material Q1 escaping from C1 in step S8 can be obtained by the following methods: obtaining the dust content and air volume data at the outlet of C1 through calibration, and then calculating Q1; when the power or current of the elevator is the same under the two working conditions of no kiln ash entering the kiln and kiln ash entering the kiln, the difference in the amount of raw material fed is the amount of kiln ash; under the condition of being equipped with a kiln ash silo with weighing function, Q1 can be obtained directly through the program.

8. The method for calculating the output of cement kilns and raw material mills according to claim 2, characterized in that, The formula for calculating the real-time clinker production value in step S9 is: In the formula, Q is the amount of raw meal entering the kiln, Q1 is the amount of raw meal escaping, and K1 is the theoretical material consumption. When conveniently calculating the output of the kiln system, the ratio of raw meal to clinker entering the kiln is taken as a fixed value K1. The formula for the clinker output value is: .

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