Cement Clinker Production System with Fluorine Control
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Solution Overview
Problem
Existing methods for producing cement clinker at lower temperatures face challenges in accurately measuring and controlling the fluorine and free lime content, leading to difficulties in producing high-quality cement due to volatilization and degeneration of samples during analysis.
Innovation Solution
A cement production system that includes a test sample-analyzing system with X-ray diffraction and fluorescent X-ray analyzers to prepare and measure beads or pressed samples of raw materials and clinker, allowing for precise quantification of fluorine and free lime content, and adjusting the supply of mineralizers and fuel accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fluorine source and sulfur source are added as mineralizer to lower burning temperature, then burning temperature can be reduced by about 100°C, but accurate measurement and control of fluorine and free lime content becomes difficult due to sample volatilization and degeneration during analysis
Solution Approach 1:
The patent applies preliminary action by adding the fluorine source and sulfur source to the raw material mixture before burning, rather than during the analysis stage. This allows the mineralizers to be incorporated into the clinker structure beforehand, enabling accurate measurement of their content in the final product without the interference of sample volatilization that would occur if measured separately. The preliminary incorporation ensures the mineralizers are stably bound in the clinker matrix, making them measurable by standard analytical methods.
2Use of energy by moving object
If mineralizer amount is increased to further lower burning temperature, then energy consumption decreases, but mineralizer coating in the kiln and pre-heater increases causing operational problems
Solution Approach 1:
The patent implements feedback control by measuring the actual fluorine and sulfur content in the produced clinker using X-ray fluorescence analysis, and then adjusting the amount of mineralizer added in subsequent production cycles. This closed-loop control system ensures that the optimal amount of mineralizer is used - sufficient to achieve the desired temperature reduction and energy savings, but not excessive to cause harmful coating buildup in the kiln and pre-heater. The feedback mechanism maintains the mineralizer content within the optimal range of 0.5-5% by weight.
3Ease of manufacture
If conventional analysis methods are used to measure fluorine content, then sample preparation is simple, but fluorine volatilizes during bead melting making exact quantification impossible
Solution Approach 1:
The patent uses X-ray fluorescence analysis as an intermediary method that directly measures fluorine content in the clinker without requiring sample preparation steps that cause volatilization. This analytical technique allows measurement of fluorine in the solid clinker sample without melting or heating the sample to temperatures where fluorine would volatilize. The X-ray fluorescence method provides accurate quantification of fluorine content (0.01-5% by weight) while maintaining simple sample preparation, effectively bypassing the volatilization problem through a non-destructive measurement approach.
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
Enables the production of high-quality cement at reduced thermal energy consumption, lowering the clinker burning temperature without increasing mineralizer coating, and reduces CO2 emissions by optimizing fuel usage and mineral content.
Implementation Method 1
an X-ray diffraction analyzer; the amount of the free lime of the clinker is measured by the X-ray diffraction analyzer
Implementation Method 2
a fluorescent X-ray analyzer; the amounts of the fluorine and main components are measured by the fluorescent X-ray analyzer
Data Source
AI summary
The cement clinker production system includes: a first supplying section configured to supply a sulfur source and a fluorine source of mineralizer; a second supplying device configured to supply clinker raw material; a crusher configured to crush the mixed raw material obtained by mixing the clinker raw material with the fluorine source of the mineralizer; a kiln configured to burn the crushed mixed raw material; an introducing section configured to introduce the sulfur source of the mineralizer to the kiln; a third supplying section configured to supply fuel to the kiln; and a test sample-analyzing system configured to collect each of the mixed raw material before the burning and the clinker after the burning and to measure amounts of the fluorine, main components and free lime depending on the type collected.