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The Invention Patents List
“National High Technology Research and Development Program of China (863 Program)” Project Key Technique and Equipment of High Efficient Heat Exchange and Low Loss of Pressure Double Spout Sinter System Guiding the main trend of cement clinker sinter system, the kiln outside decomposition system undergoes the four stages of initiation, development, improvement and innovation. The “863” Project of “Key Technique and Equipment of High Efficient Heat Exchange and Low Loss of Pressure Double Spout Sinter System” is developed to enhance the heat efficiency and reduce the energy consumption and improve production capacity. Design and optimization of the sinter system (1)Emphasize unit operation According to the physical and chemical characters of cement clinker, the sinter process has been separated into several stages. The optimized design entirely ensures high separation efficiency and low resistance. In the design of the deposition furnace, we try to obtain the high yield (including high combustion efficiency, heat efficiency, reaction rate and material deposition rate), well distribution, high turbulence deposition furnace and burner system. To improve the combustion efficiency with the tinpot coal, the burner with multi-channels in the rotary kiln is designed. A new flow-controlled grate cooler with resistant grid plate is optimal comparing to the normal grate cooler. The heat efficiency of the new cooler is above 75% larger than that of the normal cooler, and the load of the new cooler is above 40 kg/m2.d larger than that of the normal cooler. The new system also reduces the flow from 3.0 Nm3/kg.clin to 2.1 Nm3/kg.clin. (2) The entire optimum is based on the cell operation and control. Under the current condition, the entire technique satisfies the requirement. The improvement of heat exchange, material diffusion rate and chemical reaction rate pushes the rotary clinker, a basic equipment of cement calcinations, to the ideal limitation. 1.The cement clinker calcinations process research and system optimum technique (1) Numerical simulation. (2) By using precalciner design expert system, optimize design and reduce investment considerably. The numerical simulation of precalciner (3) The highlight design of precalciner Based on the numerical simulation of the heat equipment in the multidimensional space, our many year’s experience are used in the design of the cement heat equipments, such as calciner, cyclone, burner. The flow field, turbulivity field, temperature field, pressure field in the rotary kiln was simulated and analyzed. 2.Features of Precalciner System (1)features of preheater Specially designed preheater system with low flow speed (14~16 m/s at input), big volute, short cylinder, guide plate, rectifier, special powder feeder, dust inhibition plate, has many good features of low resistance, high heat efficiency, wide adaptability, rational materials distribution in the system, small inner-outer circulation, anti-blocking. . It ensures technique for new factory. The characteristic parameters are shown in Table 1.
(2) features of deposition furnace ①Operating stably due to uniformly temperature and materials without overheat locally and crusting. ②The long detention time (t1=45~140 sec, t2=12~25 sec) benefits the burning of the fault coal and the materials decomposition. ③Forfluidization deposition furnace, off-line combustion with two steps reduces the air coefficient at the kiln inlet . The deposition furnace with simple design is easy to operate and control. Under the co-use of multi-point burner in particular, its more reasonable operating parametersare favorablefor reducing NOXconcentration of kiln inlet. 3. Project Target (Taking a 6000 t/dclinker product line as example) (1) Utilize the fault coal in the cement industry. The calcinations calorific value could be only 4200*4.18KJ/kg ~ 4700*4.18 KJ/kg. 100% fault coal or 35%~45% ash content anthracite is available. With the same raw materials and fuel, the yield of kiln could improves 5~10% and the consumption of coal could be reduced 5~8%. (2) Production per volume is high up to 215 kg/m3·h~232 kg/m3·h. To ensure the high production, in the design of the rotary kiln decomposing furnace we optimize the parameters of speed, transmission power, the barrel structure and so on. (3) Heat consumption of new dry rotary kiln with φ5.0*74 m is lower than 2920KJ/kg·clin. The NOx exhaust lower than 400 ppm. (4) Reducing the blocking in the preheat deposition furnace and capability to utilize the 100% high sulphur coal with over 3% SO3in the ash, which breakthrough the limitation of 2%. The utilization of resource is improved. 4. Production Capability (6000 t/dclinker product line as example) Before the update ofclinkerproduction line, heat consumption was 2900 KJ/kg·clin; the cement strength of grade was 65 MPa; deposition ratio of raw material was 97%; production per volume was 212.4 kg/m3·h. By utilizing the fault/anthracite coal burning equipment, the high efficiency furnace and the rotary kiln decomposing furnace, the production per day increases from 6000 t/d to 7200 t/d and the production per volume reaches 227.8 kg/m3·h and the heat consumption is 2860 KJ/kg·clin and the NOx exhaust is less than 400 ppm. Especially, the product line uses the fault anthracite coal with up to 40% ash entirely. All indexes reach international advanced level. ■ The cement production increases from 6000 t/d to 7200 t/d. ■ The high sulphur coal with over 3% SO3in the ash is possible to be used. ■ The cement strength of grade is over 65 MPa. This production line needs only low investment with small area. It reaches international level.
Key Technique of High Efficiency and energy-saving Cement Grinding The key technique of high efficiency and energy-saving cement grinding was the key project supported by national universities industrial, study and research program (No.CXY2009B017). The project started with the grinding theory research and equipment innovation and chased high specific surface area, particles gradation and pattern to obtain maximum benefit. By activating mechanical energy and chemical energy with high efficiency energy-saving grinding patent techniques, the particles gradation is optimized and the surface energy is reduced. It reduces the material aggregation and the material flow can be controlled. The grinding capabilities in the system are balanced and matched. All these maximize the effective work. With these techniques, the production per hour increases 20% and the power consumption decreases 20%. The specific surface area is larger than 400 m2/kg. All equipments are made in China. Technique Target and Check Index
The example of cement mill In an production line with 1.5 million tons cement per year, the cement mill, Φ4.2×13 m, outputs 200~240 t/h. The specific surface area is above400 m2/kg and the power consumption is only about 31 kwh/t.
Key Technique of High Efficiency and energy-saving Slag Grinding National Invention Patent (ZL201110371572.7) The key technique of high efficiency and energy-saving slag grinding was the key project supported by national universities industrial, study and research program (No.CXY2009B017). The project started with the grinding theory research and equipment innovation and chased high specific surface area, particles gradation and pattern to obtain maximum benefit. By activating mechanical energy and chemical energy with high efficiency energy-saving grinding patent techniques, the particles gradation is optimized and the surface energy is reduced. It reduces the material aggregation and the material flow can be controlled. The grinding capabilities in the system are balanced and matched. All these maximize the effective work. With these techniques, the production per hour increases 20% and the power consumption decreases 20%. The specific surface area is larger than 420 m2/kg. All equipments are made in China. Technique Target and Assessment Index
Technique Index of Slag Micro Powder
The slag mill (Φ4.2×13 m) yields 120~160 t/h. The power consumption is 38~46 kWh/t. The specific surface area of the slag micro powder is 420~500 m2/kg. The exhaust gas is less than 30 mg/Nm3. The noise at500 mfrom the production area is less than 60 dB at day and 50 dB at night. The slag micro powder productions are up to national standard S105, S95, S75 and so on. The entire system is made in China. The system has high yield capability and low power consumption and low pollution.
Key Technique to Activate Magnetic Mineral Slag National Invent Patent: No. 201010123663.4 The key technique to activate magnetic mineral slag was funded by national high technology construction project. This technique utilizes mineral slag activity and magnetic characteristics to reduce solid surface energy and weaken the structural capability of solid materials. It breaks through the bottleneck of other techniques. By optimizing particles pattern through mechanical and chemical energy, the surface activity and the potential gelatinization are enhanced. The high activity mineral slag micro powder product technique was developed and the entire equipments are made in China. It realizes harmlessness and high efficient resource utilization and achieves the goal of power-saving and emission-reduction and sustainable development. Technique Target and Check Index Technique Target: By using magnetization technique and high efficiency Check Index: Main contents and techniques Magnetic mineral slag activation technique; the key preparation technique of magnetic mineral slag active agent; high efficient grinding technique of mineral slag cement; the key application technique of magnetic mineral slag active agent in mineral slag cement grinding; the demonstrating product line of high efficient grinding system. Technique Features: The high efficient magnetic mineral slag active agent is produced with surfactant activation technique and magnetic characteristics. Low cost contents design and preparation of magnetic mineral slag active agent improve the cost performance of it and promote the wide applications. Through combining mechanics energy and chemical energy and material surface energy, the mineral powder can be utilized efficiently by mixed into cement concrete with high ratio. The product yield increases 10%~20% and power consumption reduces 15%. It’s possible to optimize the particle gradation and improve specific surface area and activation index. The techniques have been applied in several provinces including Shanxi, Inner Mongolia, Liaoning, Henan, Jilin, Heilongjiang, Yunnan, Guizhou etc. The economic benefit and society benefit are large.
Green Ecology slag Powder and Cement Common integrated grinding new technology Hubei Province High Technology Industrial Development Special Project: 2012BCA20002 Several important key common integration techniques were broken through and the patents are applied. The first product line in domestic that can grind mineral slag and cement high efficiently realizes the optimal yield, quality and power consumption. With low power consumption, low pollution and low resource consumption characteristics, the green ecology mineral slag and cement common integration grinding technique can utilize the industrial solid waste as renew resource and archive the great goal of decrement, reuse, resource and high value. It leads power-saving, material-saving, carbon emission reduction and benefit improvement in the whole building materials industry. The applications of the green ecology mineral slag and cement common integration grinding technique achieve the multiplier effect for the companies with the limitation of land, human and capital. It becomes the new point of growth for the long-term development of the companies in new economic environment. It’s in keeping with the national development planning for the recently emergent industries and demonstrates a model of sustainable development and high efficiency resource utilization for the companies. Comparison between the existing system and the integration system of Φ3.2*13mgrinder for slag powder and cement.
Comparison between the existing system and the integration system of Φ 4.2*13mgrinder for mineral powder and cement.
ResourceRecycle and Reuse of Steel Slag byFeaturedSelection National Invention Patent: 201210200634.2 This technique belongs to industrial solid waste recycle field. Our company owns this intellectual property of steel slag concentration and recycles technique. Besides recycle steel, it can produce the steel slag low heat Portland cement according with the national standard requirements. It reduces the cost of production and power consumption and land occupation. It also protects the ecology environment and achieves very good economic, society and environment benefit. 1.System Features: The productions include steel particles, steel powder and S65 steel slag micro powder. For example, if the steel slag contains 25% iron, 2% iron particles and 15% iron powder and 83% steel slag micro powder can be produced. (1)Iron Particles: >90% steel content, grain size 1~10mm. It can be recycled by steel mill and the price is up to 2000 RMB/ton. (2)Iron Powder: >65% iron content, specific surface area 150 m2/kg. It also can be recycled by steel mill and the price is up to 800 RMB/ton. (3)S65 Steel Slag Micro Powder: <8% iron content, specific surface area 450 m2/kg, activity up to S65. It can be utilized in commercialconcrete batching and mixing plant. The price is up to 160 RMB/ton. (4)Take aΦ4.2*13m ball-milling steel slag grinding system for instance. Every year it can produce 15,480 ton iron particles with 31 million yuan and 116,100 ton iron powder with 92.9 million yuan and 642,420 ton steel slag micro powder with 102.8 million yuan. The total sales proceed is 226.7 million yuan. The profit of production line per year can reach 137 million yuan by considering 120 yuan/ton cost of production. 2.Quality Index of Steel Slag Micro Powder Production (1)Specific Surface Area: >450m2/kg (2)Activity Index: >55% for 7 days, >67% for 28 days (3)Free CaO Content: ≤5.0% (4)Metal Iron Content: ≤1.0% (5)MgO Content: ≤13% 3.Investment Analysis (Φ3.2×13m andΦ4.2×13m ball-milling systems)
High Efficient Utilization Technique of Tailings National Invention Patent: ZL2011110432856.2 This technique takes tailings to produce composite Portland cement. It breaks through tailings utilization. After analysis the physical and chemical characteristics of tailings , modify and activate tailings to reasonable compositionratio. It ensures tailings application amount, meanwhile the advantage of tailings Portland cement is prominent. 30%~50% cementing materials can be saved. It can apply widely in cement building materials industry. (2)Physical Active Agent By physical activation of high efficient grinding, tailings becomes micro powder, such as manganese slag. The active composite appear from the glass-like solid. It increases the specific surface area of the manganese slag and makes the active composite mixing with water during hydration.
(3)Chemical Active Agent After doped with magnetic surfactant, the activated tailings (such as manganese slag) sample showed higher early rupture strength and stronger compressive strength. With increasing the active agent, the sample strength decreases first and then increases. The optimal doping amount is about 2%.
(4)Performance Index Tailings utilization as resource is a high efficient green produce model of waste recycle and energy conservation and environment protection and carbon emission reduction. The performance index of the manganese slag for instance is following. (1)The activity of manganese slag is up to 85% after by physical and chemical activation. It can replace up to 20~40% cement in the green concrete. (2)Amount of manganese slag and slag micro powder can be mixed into cement to produce Grade PC32.5 green composite cement. (3)The manganese slag micro powder with the specific surface area of 400~600 m2/kg is available to be produced. The slump of the C30 concrete prepared with this micro powder is 18~22cm and the sulfateerosion-resisting is larger than 0.9. (4)The engineering design of the manganese slag micro powder production line is ripe and perfect and adaptable. We have the design and manufacturing capacity of the production line. It can applied to the construction design of manganese slag micro powder production line with 0.1~1 million tons output per year. The benefit of manganese slag micro powder is about 45 yuan/ton. Comparison of the cement milling plant doped with manganese slag
(5)Study of Preparation and Characteristics of the Concrete Doped by Manganese Slag Micro Powder and Limestone Powder Main Research Content: 4.Research of the optimal proportion of manganese slag micro powder and limestone powder 5.Research of the mixture properties and hydrating capacity and microstructure 6.Research of chemical erosion-resisting By a series of experiments, the results can be extracted. (6)The optimal proportion of raw materials in C30 concrete prepared by manganese slag micro powder and limestone powder is 191kg/m3cement, 152.8 kg/m3manganese slag micro powder, 38.3 kg/m3limestone powder, 1222 kg/m3crushed stone, 630 kg/m3sand, 168 kg/m3water and 5.7 kg/m3water reducing agent. (7)The mechanism in the concrete with manganese slag micro powder and limestone powder is that the limestone is physical filler and the manganese slag micro powder acts as chemical activation. With the optimal proportion of these two micro powders, the early and late strength of the concrete are enhanced. (8)In the seawater erosion environment, the concrete strength with manganese slag micro powder and limestone powder can be kept better than that of the standard common cement due to the generation of hydrationcalcium tetrachloroaluminate and the decrease of hydrated lime. The presentation quality and the seawater erosion-resisting are better. Using Tailings to produce Portland cement and concrete is feasible in technology. The quality is stability and reliable. The economic benefit is good.
Super Grinding Activation of Raw Materials National Invention Patent: ZL201110273458.0 The fineness of raw materials is an important factor to form clinker in kiln. The fineness of raw materials satisfies gradation and the constituent in the raw materials can mix uniformly. It makes the constituent in the raw materials to keep each other adequately. The reaction speeds of CaCO3decomposition and solid reaction and solid-liquid reaction increase. It is favorable to absorb the free CaO. To overcome the shortage of existing technique, super grinding activation of raw materials can develop the grinding capacity of existing equipments and increase the specific surface area of cement raw materials. The grinding efficiency becomes better. Optimal particles gradation of cement raw materials can promote the raw materials calcinations to complete physical and chemical reactions rapidly. It can improve gelatinization of the cement clinker a lot and decrease the cost of production and power. The milling time of cement raw materials and the specific surface area
Particle constituents of raw materials with 0.15% activator
Heat Block Double Sliding Shoes Mill National Utility Model Patent: 201120391189.3 This patent overcomes the following problems. 1.The inherent law of heat conduction in the microscopic region between roller and barrel of large double sliding shoes mill. 2.The key common problem of heat conduction and heat block coefficient. This patent realizes the renovation of production techniques in the large double sliding shoes mill. (6)Perform the computer simulation of the heat conduction between the roller and the barrel of the double sliding shoes mill. (7)The heat conduction per area is reduced efficiently. Realize the heat block. (8)Keep the temperatures at mill head and tail less than 60°C. (9)Keep the domestic large double sliding shoes mill to produce continuously. High Efficient Classification Separator The high efficient classification separator can be applied in superfine micro powder mill system to treat slag micro powder, steel slag micro powder, fly ash and other large amount industrial solid waste. It can replace the tornadotron and the circulating fan in the traditional cement mill technique. It also reduces the investment and power consumption. The low equipment failure rate saves the maintenance cost. The simplifiedproduction process simplifies the operations. The relation among the materials flow, airflow and powder concentration capability in the separator is solved. The high efficient classification separator is the key equipment to increase capacity and improve quality with more appropriategranulometric distribution. The specific surface area of materials is tunable among 150~350 m2/kg by changing the rotor speed. Comparing to the existing production line, the capacity increases 15%~30% and the power reduces 10%. More appropriategranulometric distribution is in the region of 3μm~32μm. Technique Target and Check Index 3.The capacity per hour icreases 15%~30%. 4.The specific surface area of the semi-finished products is tunable in the region of 150~350m2/kg. 5.The power reduces 10%.
Key Technique and Equipment of High Efficient Power-saving Waste Gas Treatment System in Large Mill The key technique and equipment of high efficient power-saving waste gas treatment system in large mill is the key project supported by national high grade school industrial, study and research program. Starting from the key waste gas treatment techniqueof slag powder preparation system, against the fragile and hard grinding problems of high water content slag, the waste gas treatment system of large slag powder mill must have multi functions simultaneously. The powerful collection capability of high concentration dust can release the stress of the mill system and increase the output. As the waste gas treatment system, it can treat high air quantity and high water content. The system resistance and the emission concentration are low. The whole system is optimized to control materials flow rate availably and to balance the milling capacity of various warehouses and reduce the over milling. The effective work to satisfy grain size requirement is maximization. The resistance in the dust collection system has been reduced 800 Pa and the yield per hour increases 20%. The power consumption reduces 20%. The specific surface area of slag powder is larger than 420 m2/kg. The whole system is made in domestic. Technique target and check index (The yield of system is 120~160 t/h for instance) 1.The flow rate of dust collection system id 37×104m3/h. The differential pressure between the entrance and the output. 2.The water content of materials can be up to 20%. 3.The power consumption reduces 20%. 4.The dust emission content is less than 30 mg/Nm3.
Various Kind of Coal Adaptable Four Channels Burner National Utility Model Patent: ZL200820081786.4 The various kind of coal adaptable four channels burner is the high technology achievement of national high technology research development plan (863 plan). According to the coal pattern and burn property, the key technique is to build the evaluation system suitable to the coal burn property in the new dry method cement produce. Whole parameters in the system are optimized. The mixture rate of coal fines and air in this burner is adjusted by applying the strong vortex flow theory. The various kind of coal adaptable four channels burner has high burning efficiency and strong adaptability. The faulty high-sulphur coal with 35%~45% ash content and 5%~8%Volatile matterand 4000~4500kcal/kg is available. This technique has been applied in many provinces. The technical performance features: ■ 100% faulty coal and anthracite are available to burn stably. The life of the burner is long. ■ The mixture coal (bituminous coal and high-sulphur coal) is available. ■ The high-sulfur coal with more than 3% SO3in the coal ash is available. ■ The structure of the burner is simple. The burning state can be adjusted easily with stable cycle vortex, high temperature, and smallfluctuation peak, high burning efficient and low blocking probability. ■ It can be used at high altitude localities. ■ The capacity of the kiln is high and the quality is stable. ■ It saves coal and power. The primary air reduces a lot to 5%~7% and the NOxemission decreases. The performance of the burner is very good.
Radiation shielding Cement with Novel Coordination Structure and Multi-Shielding National Invention Patent: 201210200974.5 The industry of world is high speed developing accompanied by the massiveconsumption of energy and resource and the severely destroyed environment. The massive consumption of energy and resource exhaust the fossil energy rapidly. All nations put the developments of new clean energy as the national strategy. The nuclear energy develops quickly due to the limitation of the wild energy and the light energy. Since the nuclear energy emerged, it has attracted a lot of attention from the world and applied wildly in military affairs, education, scientific research and medical science. To solve the problem of the existing radiation-shielding cement, this project starts with the ion coordination consolidation and the composition optimization, and mixes the well neutron-shielding B atoms and the well x-ray and γ-ray shielding Ba and Sr atoms into the raw materials of cement，makes its occupies different of atomic location, reach the effect of shielding neutron-radiation and γ, X rays simultaneously, prepare the new-type radiation-shielding cement clinker with steady coordination structure, superior multivariate radiation-shielding performance, and good thermal stability in one, and analyzes its microscopic structure, expounds the effect of microstructure on material properties.This item belongs to independent innovation, advanced, and forward-looking, will lay the technology base in a wide range of research and application of radiation-shielding cement, and has important theoretical significance and engineering application value.
Key Technique of Flue Gas Control and Denitration in the Industrial Kiln The restrictive target of the atmospheric pollutants about NH3 and NOx has been written in the national 12th Five-Year plan. The existing denitration method needs amount investment and use-cost. The enterprises are unbearable. To cement burning system as the main research object, according to combustion characteristics of cement kilnand large dry cement production process, R & D technology, this project researched the cement sintering system and developed the key equipment and technique of double spout sinter system with high heat exchange and low pressure loss, which high yield of decomposition systemout of kiln. It realizes high burning efficiency and heat efficiency and reaction rate and the decomposition rate of materials. The decomposition furnace with uniform distribution and high vortex and the appropriate burning system can depress and reduce the NOx. Use SNCR-SCR denitration technique to improve the denitration efficiency. The NOx emission of the cement kiln reaches the leading level in domestic. 1.The removal efficiency of NOxis 85~95%. 2.The NOxemission is only 100~200 mg/Nm3, for producing 0.18~0.36kg/t cement clinker. 3.The SO2emission is only 100~200 mg/Nm3, for producing 0.18~0.36kg/t cement clinker.
By applying the key technique of flue gas control and denitration in the industrial kiln, the problems of the existing technique, which are high investment and low cost performance and complex technics and bad operability and high power consumptionand high running cost, can be solved. Especially in the industrialization process, the NOx emission increases rapidly and the pressure of emission reduction is high. This new denitration technique can relieve the pressure of emission reduction and improve the technical progress of manufacturing and environmental protection industry. It improves atmospheric environment and save the energy. The world becomes resource-saving and environment-friendly. It creates better condition to improve the conditions of human existence and to develop the circular economy. |
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