Full Analysis of New Energy-saving Lime Kiln Vertical Kiln Construction Technology
With the promotion of global carbon neutralization target, energy conservation and consumption reduction technology of lime shaft kiln has become the core direction of industry transformation. The new energy-saving lime shaft kiln achieves leapfrog improvement of energy efficiency through structure optimization, combustion system innovation and intelligent control.
In terms of structural innovation, modern shaft kilns are designed in a compact manner to optimize the aspect ratio and reduce thermal inertia loss. For example, a twin-chamber shaft kiln improves the thermal efficiency to more than 90% through alternate calcination and heat storage mechanisms. The thermal insulation layer of the kiln body is made of nano aerogel composite material, matched with the four-layer refractory brick masonry process, the kiln skin temperature can be controlled within the ambient temperature+60 ℃, and the heat loss is reduced by 40%.
Combustion system upgrade is a key breakthrough in energy conservation. Oxygen-enriched combustion technology can increase the oxygen concentration of combustion air to 25% - 30%, increase the flame temperature by 150-200 ℃ and reduce fuel consumption by 12% - 18%. Pulse combustion control and intelligent air and coal proportioning system, combined with real-time monitoring of temperature in the kiln, COconcentration and other parameters, realize dynamic heat supply regulation to avoid excessive combustion.
The introduction of intelligent control system enables the production process to realize the whole process digital management. The PLC+DCS system integrates AI algorithm, which can predict the decomposition characteristics of raw materials and automatically adjust the calcination curve. For example, the third generation of environmental protection shaft kiln controls the over burning rate within 3% through the modular electronic control system, and the product quality standard deviation is reduced to 0.8%.
Further tapping energy conservation potential by waste heat cascade utilization technology. The waste gas of 300-400 ℃ at the kiln tail is sent to the waste heat boiler to generate steam, which is used for raw material drying or power generation, and the comprehensive energy efficiency of the system is increased by 25%. Gas-solid two-phase flow technology is innovatively adopted for the suspension calcining shaft kiln, so that the limestone powder can be decomposed quickly in suspension state, and the energy consumption per unit product is reduced by 35% compared with the traditional process.
These technical breakthroughs have reduced the energy consumption of the new shaft kiln process to below 130kgce/t, saving 15% - 20% energy compared with the industry average level. With the popularization of maglev fan, frequency control and other auxiliary technologies, the lime shaft kiln is accelerating its evolution towards the direction of zero carbonization, providing key technical support for the green transformation of the building material industry.
