Fly Ash Unburned Carbon Removal in Cement Manufacturing
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Solution Overview
Problem
The existing methods for using fly ash in cement manufacturing are limited by the difficulty in completely removing unburned carbon, which restricts the quantity of fly ash that can be used due to its impact on cement quality, making it challenging to increase fly ash utilization while maintaining unburned carbon content within permissible ranges.
Innovation Solution
A cement manufacturing apparatus and method that includes a removal means for unburned carbon from gypsum, allowing simultaneous removal of unburned carbon from both fly ash and gypsum, followed by grinding these carbon-free materials with clinker to produce cement, enabling increased fly ash usage while controlling unburned carbon content within acceptable limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If fly ash is added to cement to reduce costs and increase utilization of waste material, then the quantity of fly ash used increases, but the unburned carbon content in cement increases beyond permissible range
Solution Approach 1:
The patent applies preliminary action by removing unburned carbon from fly ash before the fly ash is mixed into cement. This pre-treatment step ensures that the harmful unburned carbon is eliminated in advance, allowing higher quantities of fly ash to be used without compromising cement quality standards.
Solution Approach 2:
The patent extracts the harmful unburned carbon component from the fly ash material through separation processes. By taking out the unburned carbon before mixing, the patent enables increased fly ash utilization while maintaining acceptable unburned carbon content in the final cement product.
2Object-affected harmful factors
If conventional fly ash processing methods are used to remove unburned carbon, then some unburned carbon is removed, but the quantity of unburned carbon eliminated is limited and cannot perfectly remove unburned carbon
Solution Approach 1:
The patent merges multiple separation techniques into a comprehensive processing system that combines different methods for removing unburned carbon from fly ash. This combined approach achieves more effective and complete removal of unburned carbon compared to single conventional methods, enabling higher fly ash utilization.
3Object-affected harmful factors
If the quantity of fly ash is limited to control unburned carbon content, then unburned carbon content remains within permissible range, but the utilization of fly ash and waste material treatment efficiency decrease
Solution Approach 1:
By performing preliminary removal of unburned carbon from fly ash before mixing with cement, the patent enables higher quantities of fly ash to be used while maintaining permissible unburned carbon content. This pre-treatment step resolves the conflict between fly ash utilization efficiency and quality control.
Solution Approach 2:
The patent incorporates feedback mechanisms to monitor and control the unburned carbon content throughout the processing and mixing stages. This feedback control allows optimization of fly ash quantity to maximize utilization while maintaining acceptable unburned carbon levels in the final cement product.
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 reduces unburned carbon content in cement, allows for greater fly ash utilization, decreases facility and operation costs, and ensures cement quality by measuring and calculating the optimal fly ash quantity based on unburned carbon content measurements.
Implementation Method 1
adding frothing agent to the slurry; generating air bubbles while agitating the slurry; causing unburned carbon contained in the fly ash to adhere to these air bubbles; removing the unburned carbon from the fly ash by removing the air bubbles
Data Source
AI summary
A cement manufacturing apparatus capable of increasing quantity of fly ash used in the apparatus while controlling unburned carbon content in cement within a permissible range. The cement manufacturing apparatus comprises a removal means for removing unburned carbon from gypsum, and a grinding means for grinding gypsum from which unburned carbon is removed by the removal means together with clinker to generate cement. With the apparatus, total unburned carbon content in cement can be reduced, and the quantity of fly ash used in the apparatus can be, increased by the reduced amount of unburned carbon. The removal means can remove unburned carbon contained in gypsum as well as unburned carbon contained in fly ash, and the grinding means may grind the fly ash from which unburned carbon is removed together with the gypsum, from which unburned carbon is removed, and clinker.