Cement Clinker Filter Unit Temperature Control via Clean Gas Recirculation
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Solution Overview
Problem
In cement clinker manufacturing systems, filter units often operate at partial load due to fluctuations in oven system operations, leading to inefficiencies in thermal energy recovery and potential damage from high temperatures or dust-laden gases.
Innovation Solution
The system recirculates purified gas (rein gas) back into the raw gas stream before it enters the filter unit, using a flow regulation element and a control device to adjust the gas mixture's temperature to a target level, thereby optimizing filter unit utilization and thermal energy recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ambient air is used to cool raw gas before the filter unit, then the filter unit is protected from thermal damage, but the thermal energy recovery efficiency is reduced due to the lower temperature of the cooled gas
Solution Approach 1:
The patent introduces a recirculated clean gas as an intermediary cooling medium between the raw gas and the filter unit. This recirculated gas, which has already passed through the filter and heat exchanger, serves as a mediator that cools the raw gas while retaining thermal energy within the system, thus protecting the filter unit without significant thermal energy loss.
Solution Approach 2:
The patent recovers and recirculates the clean gas that has exited the heat exchanger unit back to the inlet of the filter unit. Instead of discarding this gas or using ambient air for cooling, the system recovers it and reuses it as a cooling medium, thereby maintaining thermal energy within the system while still protecting the filter unit from excessive temperatures.
2Adaptability or versatility
If the filter unit is dimensioned for maximum expected gas volume to handle operating fluctuations, then the system can accommodate peak loads, but the filter unit operates at partial load most of the time, reducing efficiency
Solution Approach 1:
The patent ensures continuous useful action by recirculating clean gas through the filter unit. This recirculation creates a continuous flow that keeps the filter unit operating at a more consistent and optimized load level, rather than experiencing large fluctuations between idle and peak capacity, thereby improving overall productivity and efficiency.
Solution Approach 2:
The system implements feedback by recirculating the clean gas back to the filter unit inlet. This creates a closed-loop system where the output of the filter unit is fed back as an input, allowing the system to maintain stable operation and optimize filter unit utilization across varying production conditions.
3Productivity
If more clean gas is recirculated to the filter unit inlet, then filter unit capacity utilization is improved, but the temperature of the gas mixture increases, risking thermal damage to the filter unit
Solution Approach 1:
The system uses feedback control by continuously monitoring the temperature of the gas mixture and adjusting the recirculation rate accordingly. The control device regulates the flow of recirculated clean gas to maintain the gas mixture temperature below the maximum operating temperature of the filter unit, thereby optimizing filter capacity utilization without risking thermal damage.
Solution Approach 2:
The patent implements dynamic adjustment of the recirculated clean gas flow rate based on real-time temperature conditions. The system can adaptively change the recirculation quantity to match varying operational conditions, ensuring both high filter unit utilization and thermal protection through continuous optimization.
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 enhances the recovery of thermal energy by utilizing the rein gas's higher temperature, improves filter unit efficiency by maintaining optimal operating conditions, and reduces the risk of damage from excessive temperatures.
Implementation Method 1
mixing the clean gas with the raw gas to form a gas mixture upstream of the filter unit... the recirculated clean gas is cooler than the raw gas exiting the clinker cooler, so that the raw gas can be cooled by the recirculated clean gas
Implementation Method 2
a heat exchanger unit for recovering thermal energy from a clean gas exiting the filter unit
Data Source
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AI summary
The invention relates to a cement clinker production plant (1) comprising: a kiln plant (2); a clinker cooler (4); a filter unit (29) for dust removal from a raw gas; a heat exchanger unit (30) for recovering thermal energy (E) from a clean gas (24) exiting the filter unit (29), wherein the heat exchanger unit (30) is fluidically connected downstream of the filter unit (29); a clean gas recirculation (32) for at least partial recirculation of the clean gas (24) and mixing of the clean gas (24) with the raw gas (18) to form a gas mixture (25) upstream of the filter unit (29), wherein the clean gas recirculation (32) comprises at least one flow control element (27a) for adjusting the quantity of recirculated clean gas (24);and a control and/or regulating device (26) configured to control and/or regulate the temperature (T25) of the gas mixture (25) containing the raw gas (18) and the recirculated clean gas (24), which is directed into the filter unit (29) for dust removal, by adjusting the flow control element (27a) according to a setpoint temperature (Tset). Furthermore, the invention relates to a method for operating a cement clinker production plant (1).