Pellet Flue Gas Circulation and Waste Heat Recovery
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Solution Overview
Problem
The existing pellet production processes, particularly the grate-rotary kiln process, face challenges with high energy costs and environmental pollution due to inefficient flue gas treatment and waste heat utilization.
Innovation Solution
A pellet flue gas circulation and waste heat utilization system is introduced, which includes a flue gas circulation unit and intelligent control equipment. This system recycles flue gas and waste heat within the process, utilizing it to maintain stable production parameters and reduce waste gas discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flue gas is directly discharged into the atmosphere, then the treatment cost is reduced, but environmental pollution increases and energy is wasted
Solution Approach 1:
The patent converts harmful flue gas directly discharged into a beneficial resource by recycling it back to the rotary kiln inlet. The flue gas, which was previously wasted and polluting, is now utilized to preheat the incoming air and fuel mixture, transforming an environmental hazard into an energy source that reduces both pollution and energy consumption.
Solution Approach 2:
Instead of discarding flue gas through direct discharge, the patent recovers its thermal energy and compositional value by routing it back to the rotary kiln inlet. This recovery process captures both the heat content and the gaseous components for reuse in the combustion process, eliminating waste and reducing emissions.
2Device complexity
If waste heat is not utilized, then the system complexity is reduced, but energy consumption increases
Solution Approach 1:
The system achieves self-service by using the flue gas itself to provide the preheating function that would otherwise require external energy input. The hot flue gas naturally circulates back to the inlet, where its thermal energy automatically preheats the incoming air and fuel mixture, eliminating the need for separate heating equipment while reducing overall energy consumption.
3Loss of energy
If flue gas is recycled to the rotary kiln inlet, then waste heat utilization increases, but the flue gas temperature and composition must be controlled
Solution Approach 1:
The patent implements dynamic control by adjusting the recycling ratio of flue gas based on real-time process conditions. The system can vary the amount of flue gas recycled to the rotary kiln inlet to maintain optimal temperature and composition ranges, allowing flexible adaptation to different operating conditions while ensuring reliable process control.
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
The system achieves net zero waste gas discharge, reduces energy consumption, and minimizes environmental pollution by effectively recycling and utilizing low and medium temperature flue gas components and waste heat.
Implementation Method 1
the hot flue gas from the annular cooler is circulated back to the grate drying section to preheat the flue gas
Implementation Method 2
the intelligent control equipment can adjust the circulating flue gas flow rate to maintain stable temperature and pressure in the drying section
Data Source
AI summary
The present application discloses a pellet flue gas circulation and waste heat utilization process and a system thereof, which relates to the technical field of flue gas treatment. The system includes a grate, a rotary kiln, an annular cooler, and ducts connecting each part. On the basis of not changing the existing process a flue gas circulation unit and intelligent control equipment are arranged additionally in the present application. The process is simple, and not only can ensure the parameter stability of the production system such as temperature, gas flow or gas pressure, but also can make full use of the low and medium temperature flue gas components and the waste heat, so as to achieve net zero waste gas discharging, energy saving and emission reduction.