Cement Calciner Temperature Distribution Control
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Solution Overview
Problem
Existing calciners in cement manufacturing plants face issues with poor fuel burnout, high carbon monoxide levels, low nitrogen oxide reduction, and overheating, leading to increased maintenance needs.
Innovation Solution
A method involving the determination of temperature distributions within the calciner and real-time regulation of fuel, preheated raw meal, and combustion air quantities to achieve optimal combustion, prevent overheating, and enhance nitrogen oxide reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If fuel quantity is increased to maintain combustion temperature, then combustion intensity is improved, but carbon monoxide levels increase and fuel burnout deteriorates
Solution Approach 1:
The calciner is divided into multiple measurement planes with temperature monitoring at multiple locations. By segmenting the combustion chamber into zones and monitoring each zone's temperature distribution, the system can identify specific areas with poor burnout or high CO levels and adjust fuel distribution accordingly, rather than uniformly increasing fuel throughout the entire chamber.
Solution Approach 2:
The system dynamically adjusts fuel quantity based on real-time temperature distribution measurements. Instead of static fuel input, the control system continuously monitors temperature at multiple planes and modifies fuel feed rates to maintain optimal combustion conditions, preventing CO accumulation while ensuring complete fuel burnout.
2Power
If fuel quantity is increased to maintain combustion temperature, then combustion intensity is improved, but nitrogen oxide reduction becomes insufficient
Solution Approach 1:
The system implements local quality control by monitoring temperature distribution at multiple planes and adjusting fuel input based on specific zone conditions. This allows creating optimal local combustion conditions that promote complete fuel burnout and enhance nitrogen oxide reduction in critical areas without compromising overall combustion intensity.
3Productivity
If combustion temperature is increased to improve fuel burnout, then fuel combustion efficiency is improved, but calciner wall damage increases due to overheating
Solution Approach 1:
The system transitions from single-point temperature monitoring to multi-plane temperature distribution monitoring. By adding the spatial dimension of multiple measurement planes, the system can detect localized overheating conditions that would be missed by single-point measurement, allowing preventive adjustment of fuel input before wall damage occurs.
4Measurement precision
If temperature monitoring points are increased to improve measurement accuracy, then temperature distribution precision is improved, but device complexity increases
Solution Approach 1:
The system implements temperature monitoring at multiple planes with a strategically selected number of measurement points that provides sufficient precision for controlling fuel burnout and detecting overheating, without unnecessarily multiplying the measurement system complexity. The multi-plane approach provides dimensional coverage that enhances precision more effectively than simply adding numerous points in a single plane.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach improves operational reliability, reduces maintenance, and ensures efficient combustion, minimizing carbon monoxide formation and preventing calciner damage from overheating.
Implementation Method 1
At least two measuring planes, each with at least one temperature measuring device for determining the temperature distribution in the respective measuring plane, are arranged in the combustion chamber
Implementation Method 2
the calciner has at least one combustion chamber designed as a riser, through which the material flow of preheated raw meal, fuel and combustion air flows from bottom to top
Implementation Method 3
The hot gases from the kiln flow through the calciner and the preheater in countercurrent to the raw cement meal
Implementation Method 4
regulating/controlling a quantity of fuel, preheated raw meal and/or combustion air in the calciner as a function of the determined temperature distributions
Data Source
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AI summary
The invention relates to a method for operating a calciner (16) of a cement production system, having the steps of: - ascertaining a temperature distribution on at least two measurement planes (34, 36) within the calciner (16), and - regulating/controlling the quantity of fuel (30), preheated raw meal (14), and/or combustion air (32) in the calciner (16) depending on the ascertained temperature distribution. The invention also relates to a calciner (16) of a cement production system, comprising a combustion chamber (44, 46), wherein the combustion chamber (46) is equipped with at least one inlet (48, 50, 64) for introducing the preheated raw meal (14) into the combustion chamber (44, 46), at least one fuel inlet (52, 54, 60) for introducing fuel (30) into the combustion chamber (44, 46), and at least one air inlet (56, 58, 62) for introducing combustion air (32) into the combustion chamber (44, 46). At least two measurement planes (34, 36), each of which has at least one temperature measuring device (40) for ascertaining a temperature distribution on the respective measurement plane (34, 36), are arranged in the combustion chamber (44, 46), and a control/regulating device is provided which is designed to control/regulate the quantity of preheated raw meal (14), fuel (30), and/or combustion air (32) into the combustion chamber (44, 46) depending on the ascertained temperature distribution.