水泥熟料冷卻機(jī)英文翻譯版

ClinkerCoolersU.Gasser/D.Brassel

PT97/14232/E(Revision1,February1999)TOC\o"1-3"1. INTRODUCTION 52. GENERALCONSIDERATIONS 52.1 HeatFlowinaKilnSystem 62.2 Definitions 72.3 Calculations 113. GRATECOOLERS 143.1 TheReciprocatingGrateCooler 14 Principle 14 History 17 ConventionalGrateCoolers(1980’s) 18 TypicalGrateCoolerProblems 21 ModernGrateCoolers(1990’s) 23 DesignHighlightsofModernGrateCoolers 25 ClinkerCrushers 33 Coolercontrol 37 CoolerDedusting 40 Developments 423.2 TheCrossBarCooler 44 Principle 44 Mainfeatures 44 StrengthsandWeaknesses 463.3 TheTravellingGrateCooler 48 Principle 48 StrengthsandWeaknesses 504. ROTATINGCOOLERS 524.1 TheRotaryCoolerorTubeCooler 52 Principle 52 DesignFeatures 52 Coolingperformance 54 Strengths/Weaknesses 544.2 ThePlanetaryCooler 55 Principle 55 Historical 56 Designfeatures 57 Internalheattransferequipment(seeFig.26) 575. VERTICALCOOLERS 605.1 TheGravityCooler(G-Cooler) 605.2 TheShaftCooler 60

SUMMARY概述Clinkercoolershavetwotaskstofulfil:熟料冷卻機(jī)有兩大作用：Recuperateasmuchheataspossiblefromthehotclinkerbyheatinguptheairusedforcombustion從孰料中回收盡可能多的熱量來加熱用于燃燒的空氣Cooltheclinkerfrom1400°Ctotemperaturesadequateforthesubsequentprocessequipment,normallyto100-200°C.把熟料從1400°C降低到適合后續(xù)工藝設(shè)備的溫度，通常為Therearemainlytwodifferenttypesofclinkercoolersinoperationwiththefollowingfeatures:主要有以下兩種不同類型的冷卻機(jī)Gratecoolers篦式冷卻機(jī)Crossflowheatexchangethroughhorizontalclinkerbedwithcoldairfrombelow.通過水平的熟料料層與來自篦板下的冷風(fēng)進(jìn)行熱交換Coolingairflowexceedingcombustionairrequirementallowslowclinkertemperatures,butnecessitatesexcess(waste)airdedusting.冷卻風(fēng)量多于需要的熱風(fēng)量可以降低熟料溫度，但是會(huì)產(chǎn)生廢氣。Moderncoolertechnologywithsophisticatedplatesandforcedaerationsystemsallowcombustionairtemperaturesexceeding1000°C.帶有精密篦板和強(qiáng)制充氣系統(tǒng)的現(xiàn)代冷卻技術(shù)可使交換后的熱空氣到達(dá)1000°CTrendtowiderandfewergrates,lesscoolingairandfixedinlets逐步加寬和減少篦板：減少冷風(fēng)和固定進(jìn)口Largestunits:10’000t/d最大能力：10’000t/dTravellinggrate(Recupol):lastunitbuiltaround1980移動(dòng)篦板：最后一套生產(chǎn)于1980年左右。Rotatingcoolers回轉(zhuǎn)式冷卻機(jī)Rotarytubecoolerswithseparatedriveorplanetarycoolerattachedtokilnshell單筒冷卻機(jī)有獨(dú)立的驅(qū)動(dòng)，而多筒冷卻機(jī)要于窯筒體相連Quasicounter-currentflowheatexchange準(zhǔn)逆流實(shí)現(xiàn)熱交換Coolingairdeterminedbycombustionair,nowasteair冷風(fēng)取決于熱風(fēng)，沒有廢氣產(chǎn)生Heatexchange(recuperation)determinedbyconditionofinternalheattransferequipment熱交換取決于固有的傳熱設(shè)備Limitedunitsize,upto3000t/d限制單機(jī)產(chǎn)量：不超過3000t/dPlanetarycoolernotsuitableforprecalcinertechnology多筒冷卻機(jī)對(duì)于預(yù)分解技術(shù)不適宜Practicallynonewinstallationbuiltanymore實(shí)際上再?zèng)]有新的設(shè)備生產(chǎn)

INTRODUCTION介紹Theclinkercoolerisavitalpartofthekilnsystemandhasadecisiveinfluenceontheperformanceoftheplant.Threekeyindicatorscharacterizeagoodcooler:熟料冷卻機(jī)是窯系統(tǒng)中重要的一局部，并且對(duì)工廠的生產(chǎn)起著決定性的作用。好的冷卻機(jī)有以下三個(gè)關(guān)鍵性指標(biāo);MaximumheatrecuperationMinimumcoolingairflowUnrestrictedavailability最大的熱回收、最小的冷卻風(fēng)量、不受限制的設(shè)備運(yùn)轉(zhuǎn)率Therehavebeenperiodicchangesintrendsduringthepastdecades.GratecoolerswerefirstintroducedbyFullerCompany(USA)around1930.Whileitsdesignwascontinuouslybeingoptimized,thegratecoolerbecamethepredominanttypeinthe1950's.Inthelate1960's,theplanetarycoolergainedpopularitywhichreacheditspeakinthe1970's,mainlyduetoitssimplicity.Largerunitcapacitieswithprecalcinertechnologymadethegratecoolerthepreferredsolutionagain.Awaveofgratecoolerreengineeringstartinginthemid1980'shasgeneratedamuchimprovedgratecoolertechnologyaswellasanewsituationonthesuppliers'side.Newproblemswereexperiencedandhavebeenorarebeingsolved.從冷卻機(jī)的開展來看，過去的幾十年來有個(gè)周期的變化。大約1930年，篦式冷卻機(jī)首先由〔美國的〕富勒公司引入，由于他的設(shè)計(jì)持續(xù)不斷地優(yōu)化，直到二十世紀(jì)五十年代，篦式冷卻機(jī)成為主要類型的冷卻機(jī)。由于多筒式冷卻機(jī)的簡便易操作，在后來的二十世紀(jì)六十年代，多筒式冷卻機(jī)變得比擬普遍，到了七十年代到達(dá)巔峰。預(yù)分解技術(shù)的單機(jī)能力加大，又使得篦式冷卻機(jī)被優(yōu)先選用。八十年代中期，篦式冷卻機(jī)的重新設(shè)計(jì)不但使得他的技術(shù)大大提高，而且供給商方面也有了新的位置。遇到的新問題已經(jīng)或正在被逐步解決。Sincecementplantshavelifecyclesof40yearsandmore,numerousunitsofeachcoolertype,planetary,rotaryorgratecoolerofoldornewdesigns,willremaininoperationformanymoreyears.由于水泥廠的生命周期為40年或者更長，每種型號(hào)的冷卻機(jī)，無論多筒的、回轉(zhuǎn)的或篦板式的，還是以前設(shè)計(jì)的或新型的，在使用上都應(yīng)該保持更長的時(shí)間。GENERALCONSIDERATIONS一般原理Theclinkercoolerhasthefollowingtaskstofulfil:熟料冷卻機(jī)履行以下三個(gè)職責(zé)：Processinternalheatrecuperationbyheattransferfromclinkertocombustionair通過從熟料到熱空氣的熱交換實(shí)現(xiàn)工藝自身的余熱利用Reduceclinkertemperaturetofacilitateclinkerhandlingandstorage降低熟料溫度便于熟料輸送和儲(chǔ)存Providemaximumcoolingvelocitytoavoidunfavorableclinkerphasesandcrystalsize提供最快的冷卻速度，以免不良孰料相和晶粒產(chǎn)生HeatFlowinaKilnSystem窯系統(tǒng)的熱流量Theimportanceofthecoolerasaheatrecuperatorcanbewelldemonstratedwithaheatflow(Sanki)diagram.作為熱回收器的冷卻機(jī)的重要性可以用熱流量圖來充分說明Figure1 Clinkercoolerandkilnsystem熟料冷卻機(jī)和窯系統(tǒng)Figure2 Energyturnover(Gratecooler)能量轉(zhuǎn)換〔篦板式冷卻機(jī)〕Definitions定義Asforothercomponentsofthekilnsystem,specificfiguresforclinkercoolersreferto1

kgofclinker.Thiseliminatestheinfluenceofplantsizeandallowsdirectcomparisonofclinkercoolersofdifferenttypesandsizes.相對(duì)于窯系統(tǒng)而言，熟料冷卻機(jī)的單位指標(biāo)指的是1

kg熟料，這樣可以消除工廠大小不同的影響，并允許直接比擬不同類型、不同產(chǎn)量的熟料冷卻機(jī)。Coolingairistheairwhichpassestheclinkerthusbeingheatedupwhilecoolingtheclinker.Itcorrespondsapproximatelytothecombustionairrequirement,onlygratecoolersallowadditionalairforbettercooling.冷風(fēng)是指在熟料冷卻的同時(shí)通過熟料于是被加熱的空氣。冷風(fēng)〔量〕大約相當(dāng)于需要的熱風(fēng)〔量〕，只有篦式冷卻機(jī)為了有更好的冷卻效果允許有多余的空氣。Primaryairistheairwhichisrequiredforproperfunctioningoftheburner.Ambientairinsufflatedbyaseparatesmallfanplustheairfromapneumatictransportsystem,amountingfrom<10%upto>30%oftheairrequiredtocombustthatfuel.Someprecalcinerburnersareequippedwithprimaryairfans(forcooling)aswell.一次風(fēng)是指到達(dá)適宜的燃燒狀態(tài)所需要的空氣，周圍的空氣通過氣力輸送系統(tǒng)中單獨(dú)的風(fēng)機(jī)吹入，風(fēng)量為燃料燃燒所需空氣的10%～30%。有的分解爐燃燒器也配置了一次風(fēng)機(jī)〔為冷卻用〕。Secondaryairisthehotairenteringtherotarykilnviaclinkercooler.Itsflowisdeterminedbythecombustionoftheburningzonefuel.Whilecoolingtheclinker,itreachestemperaturesof600toover1000°C,dependingontypeandconditionofthecooler.二次風(fēng)是指通過熟料冷卻機(jī)進(jìn)入窯系統(tǒng)的熱風(fēng)，它的風(fēng)量由燒成帶燃料的燃燒來決定。通過冷卻熟料，二次風(fēng)的溫度依據(jù)冷卻機(jī)的型號(hào)和工況不同可達(dá)600°C～1000余°C不等。Tertiaryairisthatpartofthecombustionairwhichisrequiredforcombustingtheprecalcinerfuel.Itisextractedfromkilnhoodorcoolerroof,andthentakenalongaduct(=tertiaryairduct)paralleltothekilntotheprecalciner.Itreachestemperaturesnearorequaltothelevelofthesecondaryair.三次風(fēng)是指用于分解爐燃料燃燒的一局部熱風(fēng)，它從窯頭罩或冷卻機(jī)頂部引出，通過于窯平行的管道〔三次風(fēng)管〕到達(dá)分解爐，它到達(dá)的溫度接近或相當(dāng)于二次風(fēng)的溫度。Middleair(gratecooleronly)isextractedfromthecoolerroofifdryingofprocessmaterialsrequiresatemperaturelevelwhichishigherthanthewasteair.Ifthequantityissmall,upto450°Ccanbeexpectedatnormalcooleroperation.中間風(fēng)〔只有篦式冷卻機(jī)才有〕從冷卻機(jī)頂部引出，如果烘干工藝原料需要的溫度高于廢氣溫度〔可以使用中間風(fēng)〕；如果量少，在正常的冷卻機(jī)操作情況下可以到達(dá)450°C。Wasteair(gratecooleronly)isalsocalledcoolerexitairorcoolerexcessair.Thetotalcoolingairflowfromthefansisnormallyhigherthantheflowrequiredforcombustion(=tertiary+secondaryair).Theextraair,whichhasnormallyatemperatureof200to300°C,mustbeventedtoambientviaadedustingsystem.廢氣〔只有篦式冷卻機(jī)才有〕也稱冷卻機(jī)排氣或冷卻機(jī)過?？諝狻睦鋮s風(fēng)機(jī)來的總冷風(fēng)量通常高于〔燃料〕燃燒需要的熱風(fēng)量〔三次風(fēng)+二次風(fēng)〕，多余的空氣，通常情況下可達(dá)200to300°C,，必須通過收塵系統(tǒng)排入大氣。Falseairiscoldairenteringthesystemviakilnoutletseal,burneropening,casingorclinkerdischarge.Iteitherdilutessecondaryairthusreducingrecuperatedheatoraddsloadtothewasteairsystemofgratecoolers.漏風(fēng)指通過窯頭密封、燃燒器噴嘴開口、外罩、卸熟料進(jìn)入系統(tǒng)的冷風(fēng)。它也稀釋了二次風(fēng)、降低了熱回收，或者增加了篦式冷卻機(jī)的廢氣。Specificairvolumesareairflowsperkgofclinker(m3/kgcli,Nm3/kgcli).Independentofthekilnsize,airflowsofcoolersystemscanbedirectlycompared.單位風(fēng)量是指每kg熟料的冷風(fēng)量〔m3/kgcli,Nm3/kgcli)〕，無論窯的大小，冷卻機(jī)系統(tǒng)的冷風(fēng)量能夠直接相比。Specificloadsexpresstherelationofclinkerproductiontoacharacteristicdimensionofthecooler(t/dm,t/dm2,t/dm3).Exactdefinitionsvarywithcoolertype.單位負(fù)荷是指熟料產(chǎn)量與冷卻機(jī)基準(zhǔn)尺寸的比值關(guān)系(t/dm,t/dm2,t/dm3).。精確的定義將隨冷卻機(jī)型號(hào)而變化。Radiationlossesfromthecoolercasing/shellareparticularlyimportantforplanetarycoolers,wheretheyactivelysupportthecoolingoftheclinker.輻射損失：來自冷卻機(jī)殼的輻射損失對(duì)于多筒冷卻機(jī)是特別重要的，多筒冷卻機(jī)主要在那里進(jìn)行熟料冷卻。Efficiencyexpressesthequalityofheattransferfromclinkertotheairwhichisusedforcombustionintheburningzoneandprecalcinerfiring. 效率是指從熟料到用于燒成帶和分解爐燃料燃燒的熱風(fēng)熱交換的質(zhì)量。Remark: Sincetheheatrecuperatedisproportionaltohotairusedforcombustionandtemperature,anefficiencyfigureisonlymeaningfulifitisrelatedtoaheatconsumptionfigure(resp.acombustionairflow).摘要：由于熱回收與用于燃燒的熱風(fēng)和溫度是成比例的，而且，一個(gè)效率指標(biāo)如果它與一個(gè)熱消耗指標(biāo)建立關(guān)系，它就是有意義的。Figure3 Clinkercoolers–Definitions熟料冷卻機(jī)—定義

Calculations公式Thecalculationsbelowareexamplesofheatbalanceinvestigations:下面的公式是研究熱平衡的范例：HeatinhotclinkerQcli:Qcli=mcli*cpcli*(tcli-tref)Examplewithmcli=1kg/h:tcli=1400°C:Qcli=1kg/h*1.090kJ/kg°C*(1400°C-20°CHeatinhotairQair:Qair=Vair*cpair*(tair-tref)ExamplewithVair=1Nm3/h:tair=1066°C:Qair=1Nm3/h*1.421kJ/Nm3°C*(1066°CRadiationlossQrad:Qrad=CR**A{(t/100)4-(t0/100)4}GratecoolerQrad=20kJ/kgcli(fromexperience)CoolerefficiencycoolerThesecondary(+tertiary)airrequirementsaredictatedbytheamountoffuelfedtotheburners.Perthisdefinition,theefficiencyofacoolerisgettingbetterwithincreasingkilnheatconsumption.Itisthusobviousthatacoolerefficiencyfigureisonlymeaningfulifthecorrespondingheatconsumption(orairflow)isindicated.二次風(fēng)〔三次風(fēng)〕的需求量由燃燒器的燃料喂料量決定，根據(jù)這樣的定義，一個(gè)冷卻機(jī)的效率隨著窯熱消耗量增加而提高。顯然，如果說明熱消耗量〔或風(fēng)量〕，冷卻機(jī)的效率指標(biāo)才是有意義的。

Example:production產(chǎn)量5000t/d熱消耗heatconsumption3000kJ/kgcli二次風(fēng)和三次風(fēng)溫度secondaryandtertiaryairtemperatures1066°CPrimaryairmainburner10%PCfuelratio60%Falseairandexcessairneglected(notrealistic!)Qcombair:VCombair=3000MJ/kgcli*0.26Nm3/MJ*5000/24*103=156'000Nm3/htcombair=1066°Cqcombustionair=1.421kJ/Nm3°*(1066-20)°=1486kJ/Nm3Qcombair=Vcombair*qcombair=1486*156'000kJ/h=231'816GJ/hQclinker:mclinker=5000t/d/24h/d*103kg/t=208'tclinkerfromkiln=1400°Cqclinkerfromkiln=1.09kJ/kg°*(1400-20)°=1504kJ/kgQclinker=208'333*1504kJ/kg=313'333GJ/hEfficiency=231'816/313'333*100%=74.0%Figure4 Clinkercoolertypicaldata(4-stageSPKiln,2’000t/d)GRATECOOLERS篦式冷卻機(jī)TheReciprocatingGrateCooler推動(dòng)篦式冷卻機(jī)Thereciprocatinggratecooleristhemostwidelyappliedtypeandisexclusivelyusedfornewplants.推動(dòng)篦式冷卻機(jī)是最廣泛使用的類型而且專門用于新型工廠。Principle原理Thefollowingmajorsystemcomponentscanbedistinguished:以下主要系統(tǒng)組成是顯著的Casingwithkilnhoodandconnectionsforairatdifferenttemperaturelevels帶窯頭罩的殼體，與氣體的不同溫度水平都有聯(lián)系Reciprocatinggratewithdrivesystem帶有驅(qū)動(dòng)系統(tǒng)的推動(dòng)篦板Aerationsystemwithfans,undergratecompartmentsanddirectairducts帶風(fēng)機(jī)、篦下隔倉和直接風(fēng)管的充氣系統(tǒng)Riddling(=fallthrough)extractionsystemwithhoppers,gatesandtransport帶料斗、閘門和輸送格篩的細(xì)粒出料系統(tǒng)Clinkercrusher熟料破碎機(jī)Materialtransport熟料輸送

Theclinkerispushedbytheverticalpartofthefrontedgeoftheprecedingplate.Theentiregrateconsistsofacombinationoffixedandmovingrowswhichresultsinaquasi-continuousmotionoftheclinkerbed.熟料被前端篦板前面的垂直局部推動(dòng)，整個(gè)篦板由固定排列和活動(dòng)排列組合而成，結(jié)果造成持續(xù)推動(dòng)形成熟料料床。Heatexchange熱交換

Heatexchangefromclinkertoairisaccordingtothecrosscurrentprinciple.Thecoolingairpenetratestheclinkerbedwhichislayingonthegratefromunderneathandleavesitatthesurface.Whilepassingthroughthehotclinker,theairisaccumulatingheatwhichistransferredfromtheclinker.從熟料到氣體的熱交換遵循逆流原那么，冷風(fēng)從下面穿透篦板上熟料料床到〔熟料〕外表離開，在穿過熱熟料的同時(shí)，氣體通過熱交換從熟料中累積熱量。Coolingair冷風(fēng)

Normally,ambientairisblowntounderneathofthegrateplatesloadedwithclinkerbyanumberofcoolingairfans.Deliverypressuremustbesufficienttopenetratetheclinkerbedandtocompensatefortheexpansion(increaseofactualvolume)oftheairfromheatingitup通常，周圍的空氣通過大量的冷卻風(fēng)機(jī)吹入承載熟料的篦板下面，必須有足夠的輸送壓力使得氣體可以穿過熟料料床，并且，補(bǔ)充空氣量〔增加有效風(fēng)量〕加熱。

Underidealconditions,therequiredcoolingairdependsdirectlyfromthedesiredclinkertemperature.Onepartofthecoolingairisusedforcombustioninthekiln,therestiscleanedandventedtoambient,unlessitisfurtherused,e.g.fordrying.理想狀態(tài)下，需要的冷風(fēng)量直接依賴于理想的熟料溫度，冷風(fēng)的一局部用于窯燃燒，其余的凈化后排入大氣，除非有進(jìn)一步的使用，例如烘干。Coolingcurve冷卻曲線

Asimplifiedmathematicalmodelforclinkercoolinginaconventional,optimizedgratecoolergivestherelationbetweencoolingairquantityandclinkertemperatureasfollows:對(duì)于在一個(gè)常規(guī)、完善的篦式冷卻機(jī)的熟料冷卻，一個(gè)簡單的數(shù)學(xué)公式給出了冷風(fēng)量和熟料溫度之間的關(guān)系，表示如下： withTcliin=clinkertemperatureatcoolerinlet°CTamb=ambienttemperature°CVair=coolingairquantityNm3/kgcliTheaboveapproximation(curveFig.17:Tcli=1400°C)hasbeenfoundtogivesatisfactoryresultsforconventionalgratecoolersfromvarioussuppliers.對(duì)于不同供貨商的常規(guī)的篦式冷卻機(jī)，上面的近似計(jì)算將給出一個(gè)滿意的結(jié)果。Figure5 ReciprocatingGrateCooler:DesignFeaturesHistory〔冷卻機(jī)的〕歷史ItwastheFullerCompany(USA)whointroducedthefirstreciprocatinggratecoolerinthelate1930'swithagrateslopeof15°.富勒公司〔美國〕于1930's末期引進(jìn)的第一臺(tái)推動(dòng)式篦冷機(jī)帶有一塊15°的篦板。Fluidizedmaterialrunningdownthegrateleadsto10°grateinclination.The10°coolerwaspredominantlyuseduntilthemid1950's.Problemswereencounteredwiththose10°coolerswhentheclinkerwasfineandstartedtofluidize.Asanattempttosolvethisproblem,wedgegrateplateswereused.Anotherdrawbackofthose10°coolerswasthebuildingheightrequiredforlargerunits.流動(dòng)的熟料沿著篦板逐漸慢下來，引導(dǎo)了篦板的傾斜度〔改變成〕10°。直到1950's.中期，使用這些10°的冷卻機(jī)占主導(dǎo)地位。當(dāng)熟料較細(xì)而且開始流動(dòng)時(shí)這些10°的冷卻機(jī)遇到了問題。為解決這個(gè)問題，加寬了篦板。這些10°的冷卻機(jī)的另一個(gè)缺陷是更大的體積要求的建筑高度。Inthemid1950's,thefirsthorizontalgratecoolerswereintroduced.Theywereinitiallyjust10°gratesinstalledhorizontallywithaccordinglyreducedconveyingcapacity.Someofthesecoolerswereseverelydamagedbyoverheating,duetofluidizationandaccumulationofhotfineclinkeratthefeedend.1950's中期，第一臺(tái)水平篦冷機(jī)問世。最初，他們僅僅將10°的篦板安裝為水平，相應(yīng)地減少了輸送了能力。這些冷卻機(jī)，由于熱細(xì)熟料在喂料端的流動(dòng)和累積損壞嚴(yán)重。Thisdrawbackofthehorizontalcoolerleadtothedevelopmentoftheso-calledcombicooler.Ishasone(orformerlytwo)inclinedgrateswithnormally3°slope,followedbyoneortwohorizontalgrates.Notallsuppliersfollowedthesamephilosophies,soallthreeconcepts(allhorizontal,combiandallinclined)canbefoundallovertheworld.水平篦冷機(jī)的缺陷導(dǎo)致了康比冷卻機(jī)的開展。通常有一塊〔或者以前是兩塊〕傾斜3°的篦板，安裝在一或者兩塊水平篦板的后面。并非所有的供貨商都遵循同樣的準(zhǔn)那么，所以，三種類型〔所有水平的、康比的、所有傾斜的〕被全世界應(yīng)用。Theplanetarycoolerboomperiodinthe1970'scametoanend,whenlargeproductioncapacitieswereindemand.Precalcinertechnologyrequiredgratecoolerswhicheventuallyneededtobereengineeredagain.Problemsrelatedtotheclinkerdistribution,growingawarenessofheatandpowerconsumptionaswellasthedemandforhigheravailabilityforcedthesupplierstointroducenewsolutions.InitiatedbythenewcompanyIKN,thegratecoolertechnologyunderwentsignificantchangessincethemid1980's.Moderngrateplates,forced(direct)aerationandbettergapdesignwereintroducedbyallcoolermakershelpingtoreducecoolingairflowandcoolersize.1970's，當(dāng)要求大的生產(chǎn)能力時(shí)。多筒冷卻機(jī)的繁榮時(shí)代結(jié)束了。預(yù)分解技術(shù)最終要求篦式冷卻機(jī)重新設(shè)計(jì)。問題涉及到熟料分布、熱量和能源消耗的增加也就是要求更高的能力，使得供貨商有新的解決方案。自從1980's中期，由新興的IKN公司發(fā)起，篦冷機(jī)技術(shù)經(jīng)歷了重大的變化。現(xiàn)代的篦冷機(jī)，為有助于減低冷風(fēng)量和冷卻機(jī)的尺寸，所有的冷卻機(jī)制造商都引入了強(qiáng)制〔直接〕充氣系統(tǒng)和更合理的間隔設(shè)計(jì)。Thenewapproachleadtobetterrecuperationinmostcases.However,seriouswearproblemswiththenewsystemsforcedmostofthecompaniestomodifytheirsolutionsonceagain.Today,inthemid1990's,wearestillgainingexperiencewithlatestdesigns.在無多案例中，新的方法導(dǎo)致更好的余熱利用?？墒牵孪到y(tǒng)嚴(yán)重的磨損問題迫使大多數(shù)工廠再一次修改他們的解決方案。今天，在1990's中期，我們的最新設(shè)計(jì)正在贏得實(shí)踐的檢驗(yàn)。Theultimatesolutionwouldbethewasteairfreegratecoolerwithunlimitedflexibilityandavailability.However,rightnowthecementindustrywouldbehappywithsmoothoperation,highrecuperation,lowcoolingairandnocoolerrelatedkilnstops.最好的解決方案將是篦冷機(jī)具有無限適應(yīng)性和運(yùn)轉(zhuǎn)率的廢氣釋放功能。無論如何，目前水泥廠都很幸運(yùn)，有平穩(wěn)的操作、較高的余熱利用、較低的冷風(fēng)量，而且，沒有因?yàn)槔鋮s機(jī)而導(dǎo)致停窯。Figure6 VariousconfigurationsofreciprocatinggratecoolersConventionalGrateCoolers(1980’s)傳統(tǒng)的篦冷機(jī)(1980’s)TypicalDesignFeatures主要的設(shè)計(jì)特點(diǎn)Grateplateswithroundholes帶圓孔的篦板Twotothreegrates,dependingonsize根據(jù)大小，兩或者三塊篦板Grateslope0°or3°orboth,dependingonsupplier根據(jù)供貨商，篦板傾斜度0°或3°或兩者都有Mechanicalexcenterdrivesforreciprocatinggrate推動(dòng)式篦板外心驅(qū)動(dòng)Chamberaeration充氣室Fanpressure45mbar(first)to25mbar(last)風(fēng)機(jī)壓力從起初的45mbar到最后25mbarSmallercompartmentsatinlet,largertowardsoutlet進(jìn)口倉小，越往出口越大Clinkerriddlingextractionwithhoppers,gatesanddragchain(someearlierdesigns:internaldragchainwithouthoppers)帶料斗、閘門和拉鏈機(jī)〔一些早期的拉鏈機(jī)設(shè)計(jì)沒有料斗〕格篩的細(xì)粒出料系統(tǒng)Hammercrusheratcoolerdischarge錘式破碎機(jī)在冷卻機(jī)卸料端World’slargestkilns(10'000t/dinThailand)areequippedwithconventionalgratecoolersfromCPAGwith4grates.世界上最大的窯(10'000t/din臺(tái)灣)配備了CPAG的4段常規(guī)篦冷機(jī)。StrengthsandWeaknessesofConventionalGrateCoolers常規(guī)篦冷機(jī)的優(yōu)缺點(diǎn)Strenghts優(yōu)點(diǎn)Weaknesses缺點(diǎn)Lowerclinkerendtemperatureduetohigheramountofcoolingair由于更多的冷風(fēng)量，熟料出口溫度較低Possibilityofadjustingcoolingairandgratespeedprovideshigherflexibility調(diào)整冷風(fēng)和篦板速度提供更好適應(yīng)性的可能Optimizationpossibilitiesduringoperation操作過程中的最正確可能性Wasteairhandlingsystem(dedusting,fan)required需要廢氣處理系統(tǒng)〔除塵、風(fēng)機(jī)〕Morecomplexcoolerrequireshighercapitalinvestment更復(fù)雜的冷卻機(jī)要求更高的資金投入Higherpowerconsumptionthanplanetaryortubecooler相對(duì)于多筒或單筒冷卻機(jī)更高的能量消耗Unevenclinkerdischarge/segregationleadstoseveralproblems非均勻的熟料卸料/別離導(dǎo)致的一些問題Redriver紅河Snowmen雪人Airbreakthrough(bubbling,geyser)透氣Reducedplatelife降低篦板壽命Excessiveclinkerfallthroughbetweengaps過多的熟料從縫隙間掉下來Causesandmechanismofthoseproblemsarefurtherexplainedinthenextparagraph.這些問題的形成原因和機(jī)理將在下一個(gè)章節(jié)講解Figure7 Conventionalgratecoolers:Designfeatures傳統(tǒng)篦冷機(jī)：設(shè)計(jì)特點(diǎn)

TypicalGrateCoolerProblems典型的篦冷機(jī)問題Mostgratecoolersshowatendencytooneormoreofthesysteminherentproblems,andinmanycasesthereisnorealcure.Investigationsofthecausesleadtothedevelopmentofthemoderncoolertechnology.大多數(shù)的篦冷機(jī)顯現(xiàn)出有一個(gè)或更多的系統(tǒng)自身的問題一種趨向，而在大多數(shù)的工廠又沒有真正發(fā)送過。這些原因的研究導(dǎo)致了現(xiàn)代冷卻機(jī)技術(shù)的開展。Segregation:〔熟料粗細(xì)〕別離

Duetoitsphysicalproperties,theclinkerisliftedbythekilnrotationbeforeitisdischargedintothecooler.Installationofthegrateaxisoffsetfromthecooleraxisshouldcompensateforthiseffect.However,sincedischargebehavioroffinerandcoarserclinkerparticlesdifferfromeachother,theclinkerfractionsarenotevenlydistributedacrossthegrate.Finesaredischargedlaterandarethusfoundpredominantlyontherisingsideofthekilnshell(Fig.8a).由于其物理特性，熟料在卸入冷卻機(jī)之前靠窯旋轉(zhuǎn)提升運(yùn)轉(zhuǎn)。篦板軸從冷卻機(jī)軸偏移的設(shè)置將抵消這種影響。無論如何，因?yàn)榇旨?xì)熟料顆粒卸料方式互不相同，熟料粒級(jí)不能均勻地沿篦板分布。細(xì)料卸得慢，因而發(fā)現(xiàn)主要卸在窯筒體上升的一側(cè)〔如圖8a〕。Thinclinkerbedinrecuperationzone:熱回收帶的熟料料床

Withaconventionalgratecoolerwithchamberaeration,theclinkerbedthicknessislimiteddirectlybytheinstalledcoolingfanpressureandindirectlybythequalityofcompartmentsealsanddistributionoftheclinkeracrossthewidth.Inordertoavoidoverheatedplates,theoperatorwillsetthebednothigherthanallowedtoguaranteeairflowthroughtheplatecarryingtheclinkerwiththehighestbedresistance.

Thinbedoperationleadstounfavorablyhighairtoclinkerratioandpoorheatexchangeonthesideswithconsequentlylowrecuperationefficiency.帶有充氣室的傳統(tǒng)篦冷機(jī)，熟料料床厚度直接受安裝的冷卻風(fēng)機(jī)壓力限制，間接受氣室的密封質(zhì)量和熟料分布的整個(gè)寬度限制。為防止篦板過熱，操作者將調(diào)整料床不高于允許保證風(fēng)量通過承載熟料的篦板的最高料床阻力。不當(dāng)?shù)牟僮鲗?dǎo)致氣料比偏高而且每一側(cè)的熱交換低，因而，熱回收低。Redriver:紅河

Theinfamousredriverisoneofthemostfearedproblemswithgratecoolers.糟糕的紅河是篦冷機(jī)最令人擔(dān)憂的問題之一。

Duetosegregation,fineclinkerhasalwaysitspreferredside(seeabove).由于〔粒級(jí)〕別離，細(xì)熟料總是在它首選的一側(cè)。

Differentbedresistanceoneithersideandonlyoneairchamberacrosstheentirewidthoftencausefluidizationofthefineclinkerlayingontop.Thisfluidizedclinkerdoesnolongerfollowthespeedofthegrate,butshootsmuchfastertowardsthecoolerdischargeend.Becausetheresidencetimeofthatfineclinkerismuchreduced,itdoesnotfollowthegeneralcoolingcurveandformsaredhotlayerontopoftheregularlycooled,alreadyblackclinker.Hencetheterm"redriver".兩側(cè)不同的料床阻力或只有一側(cè)氣室通過整個(gè)寬度，經(jīng)常導(dǎo)致上面的細(xì)料層流態(tài)化。流化的熟料不再按照篦板的速度，而是非?？斓厣湎蚶鋮s機(jī)的卸料口。因?yàn)榧?xì)熟料的停留時(shí)間太短，它沒有遵循一般的冷卻曲線并且在有規(guī)律冷卻的熟料，幾乎是黑熟料的上面形成紅熱層，因此，叫“紅河〞。

Itisnotthemissedheatrecuperation,buttheredhotmaterialbeingintouchwithcoolerwalls,platesandsidesealsinthecolderareawheresuchtemperaturesshouldnormallynotoccur.Prematuredestructionofthosepiecesresultsinpooravailability,highmaintenanceandultimatelyinlossofproductionandsalesrevenues.這并非未得到熱量回收，但是，紅熱熟料與冷卻機(jī)的隔板、篦板和在冷卻區(qū)域的側(cè)面密封接觸，那里通常情況下如此高的溫度式不能發(fā)生的。那些地方的過早破壞，導(dǎo)致能力下降、維修升高，最終是產(chǎn)量和銷售收入的損失。Snowman:雪人

Thestickyconsistenceofthehotclinkerleavingthekilncombinedwiththecompactionatthedroppointoftenleadstoformationofsolidclinkermountainsonthegrate.Notpermeableforcoolingair,theygrowlargeranddisturbtheflowpatternoftheclinkerinthisanywaycriticalinletarea.離開窯粘稠的熱熟料在下料點(diǎn)變得密實(shí)，經(jīng)常導(dǎo)致在篦板上形成鞏固的熟料坨〔山〕。冷風(fēng)不能滲透，他們會(huì)變大并且干擾熟料在臨界入口區(qū)域的流動(dòng)模式，Airbreakingthrough:透氣

Duetothedifferentresistanceoftheclinkerbedandthefearofoverheatedplates,toomuchairisputonthefirstgratecomparedtotheclinkerbed.Theresultisairshootingthroughthebed,hardlytakinganyheatandthusnotcontributingtotheheatexchange.

Inadditiontothat,theclinkerismixedwhichcanbeseenbythebubblingaction,andthelayeredclinkerbed(colderclinkerbelow,hotterontop)isdestroyedthusdisturbingthecrossflowheatexchangepattern.由于熟料料床的不同阻力以及擔(dān)憂篦板過熱，相對(duì)于料床把過量的空氣用于第一段篦板上。其結(jié)果就是空氣穿透料床，幾乎沒有帶走任何熱量，因而沒有產(chǎn)生熱交換。因此，由于氣泡反響注意到熟料被混合，而且，分層的料床〔冷的熟料在下面。熱的熟料在上面〕被破壞，因而，擾亂了逆流熱交換的模式。

Theresultsarelowrecuperationandtoomuchheatgoingtotheaftercoolingzone.結(jié)果就是低的余熱利用和太多的熱量帶到冷卻帶之后。

Figure8a:SegregationatcoolerinletFigure8b:Clinkerbeddeptheffectoncooling

Figure8c RedRiverFigure8d Snowman

ModernGrateCoolers(1990’s)現(xiàn)代篦冷機(jī)DesignFeatures設(shè)計(jì)特點(diǎn)Thesuccessfulclinkercoolerhas:成功的熟料冷卻機(jī)有Correctallocationofcoolingairtoclinker冷風(fēng)到熟料的正確分配

Sustainablegapwidthsintheentirecooler整個(gè)冷卻機(jī)可以承受的間隔寬度Allneworredesignedclinkercoolersareaimingattheabovetwogoals:所有最新的或重新設(shè)計(jì)的熟料冷卻機(jī)都以以上兩點(diǎn)為目標(biāo)。Moderngrateplates,designedtocopewithhightemperaturedifferences現(xiàn)代篦板和設(shè)計(jì)解決高溫差異。Inclinedinletsectionwithoutmovingrows傾斜進(jìn)口局部不要活動(dòng)排列Patternofzonesforindividuallyadjustableaerationinrecuperationzone在熱回收帶對(duì)于個(gè)別可調(diào)整的分區(qū)充氣模式Modernplatesforatightgrateintheaftercoolingzone現(xiàn)代鋼板作為緊密篦板用在冷卻帶之后New,improvedsidesealplatedesignfortightgapsandlowwear為緊致間隔和減低磨損新的、改善的測(cè)密封板設(shè)計(jì)Carefulundergratecompartmentsealing周密的篦下隔倉設(shè)計(jì)Adequatesealairsystemwithcorrectcontrol帶有正確控制的適宜的氣力密封系統(tǒng)Widerandshortercoolers;lowernumberofgrates加寬和縮短冷卻機(jī)：減少篦板數(shù)量Improvedandwearprotectedmovinggratesupportandguidance活動(dòng)篦板支撐和導(dǎo)板的改善和磨損保護(hù)Hydraulicgratedrivewithoptimizedcontrolsystem帶有最正確控制系統(tǒng)的液壓篦板驅(qū)動(dòng)Coolingairfanswithinletvanecontrolandinletnozzleformeasuringflow帶有入口風(fēng)葉控釋的冷卻風(fēng)機(jī)和用于測(cè)量風(fēng)量的進(jìn)口噴嘴Rollercrusher輥式破碎機(jī)StrengthsandWeaknessesofModernGrateCooler現(xiàn)代篦冷機(jī)的優(yōu)缺點(diǎn)Strenghts優(yōu)點(diǎn)Weaknesses缺點(diǎn)Moreconstantheatrecuperationimproved,smootherkilnoperation熱回收量多改善、平穩(wěn)窯操作Coolerinlet:improvedclinkerdistributionacrossgratewidth冷卻機(jī)進(jìn)口：改善熟料沿篦板寬度的分布Elimination/controlofredriver紅河的消除/控制Significantlyreducedgrateriddlings(clinkerfallthrough)顯著地降低了篦板的篩下細(xì)分〔熟料樓料〕Higherwasteairtemperature(valuablefordrying)更高的廢氣溫度〔對(duì)烘干有用〕Lowerheatconsumptionduetohigherheatrecuperation(coolerefficiency)由于更高的熱回收降低了熱耗〔冷卻機(jī)效率〕Reducedpowerconsumptionduetolesswasteair由于減少廢氣，降低了能源消耗Lowercivilcostduetomorecompactcooler緊湊的冷卻機(jī)降低土建本錢Lowerinvestmentduetosmallerwasteairsystem廢氣系統(tǒng)小降低了投資Reducedcostformaintenance減少維修本錢Morecomplicatedmechanicalinstallation(varieswithsupplier)較復(fù)雜的機(jī)械安裝〔隨供貨商而異〕Highersecondaryairtemp.increaseswearofnoseringandburnerrefractories更高的二次風(fēng)溫度加大了煤灰圈和燃燒器耐火襯的磨損Higheractual(m3/h)tertiaryairflowcanincreasedustentertainmentattakeoffpoint增加的三次風(fēng)量將提高取風(fēng)點(diǎn)粉塵含量Teethingproblemswithnewdesigns->designchangesstillinprogress新設(shè)計(jì)的適應(yīng)問題->設(shè)計(jì)更新不斷進(jìn)步Figure9 ModernGrateCoolers:DesignfeaturesDesignHighlightsofModernGrateCoolers現(xiàn)代篦冷機(jī)的設(shè)計(jì)亮點(diǎn)ModernGratePlates現(xiàn)代篦板Inthemid1980's,thefirstmoderngrateplateswereinstalledingratecoolersbyIKNandCPAG.Theyweredesignedforthefollowingtargets:1980's中期，第一塊現(xiàn)代篦板由IKN和CPAG公司裝置于篦冷機(jī)。這樣設(shè)計(jì)有以下目標(biāo)：Allowforlowerair/clinkerratiointherecuperationzoneforhigherrecuperation為了更高的熱回收，允許在熱回收帶的有較低的氣料比Improveclinkerdistributionacrossthegratewidth沿著篦板改善熟料分布Assurethatallgrateplatesarealwayssufficientlycooledbyair保證所有的篦板總是被空氣充分冷卻Theabovetargetswerereachedusingthefollowingideas:用以下的方法到達(dá)以上的目標(biāo)Higherbuilt-inpressuredrop提高自身壓差

Similartotheeffectofthickbedoperation,ahigherpressuredropacrosstheplatereducestherelativeinfluenceofvariationsinpermeabilityoftheclinkerbed.類似于厚熟料床操作的效應(yīng)，沿篦板一個(gè)高的壓差將減小熟料料床透氣性變化的影響。Nomorefineclinkerfallingthrough不再有細(xì)熟料落下來

Fineclinkerfallingthroughmeanslossofheatandthermalstressonthedragchain.Forforcedaeration(below)itismandatorythatnomaterialcanfallintheairductswhereitwouldcutofftheairsupply.細(xì)熟料掉下來意味著熱量損失而且在拉鏈機(jī)上有熱壓。對(duì)于強(qiáng)制充氣系統(tǒng)〔下面的〕，沒有物料落在風(fēng)管是必須遵循的，否那么空氣供給將被切斷。Forced(direct)aerationviaairducts經(jīng)過風(fēng)管強(qiáng)制〔直接〕充氣系統(tǒng)

Inordertoensurethatallplatesgetenoughair,toallowindividualallocationofairtodifferentareasandtoavoidthatairescapesthroughgaps,groupsofplatesaresuppliedwithairdirectlyviaaspecialductsystem為了保證所有的篦板得到足夠的風(fēng)量，允許可能風(fēng)量的個(gè)別分配到不同區(qū)域而且防止了空氣從間隔中逸出，這些篦板通過