With the promotion of the new dry process cement technology, the development achievements of China's cement industry in recent years are obvious to all: The annual cement output exceeds one-third of the world's total cement output, ranking first in the world; in 2007, the cement output was 1.36 billion tons. A record high. Relevant aspects expect that China's cement production in 2010 will reach 1.72 billion tons.
At present, the large scale of cement production has become the development trend of the cement industry. As of the end of 2007, according to the statistics of the China Cement Association, there are 798 new dry process lines with a total annual production capacity of 607,042,000 tons of clinker. Among them, 340 to 5,000 tons/day scale production lines account for 45.37% of the total clinker production capacity; 5,000 tons/day and above scale production lines total 137, accounting for 36.80% of the total clinker production capacity. At present, the world's largest cement clinker production line has reached 10,000 tons/day, and there are four in China.
This change puts forward higher requirements for the energy saving, higher operation rate, and saving of mineral resources in the cement industry, which in turn requires the further enlargement, localization, and simplification of the cement equipment. For this reason, in 2002 the former State Economic and Trade Commission approved the Tianjin Cement Industry Design and Research Institute, under the China National Materials Corporation, to preside over the development of a national major technical equipment development project called “10,000 tons/day of new dry process production technology and complete equipment for cement clinker”. After the successful development of this project, it possessed many technological innovation points, broke through a large number of major key technologies, owned 13 Chinese patents, and thus won the 2007 National Second Prize for Scientific and Technological Progress.
Many core equipment innovations
In a conference room of the Tianjin Cement Industry Design and Research Institute, Bian Hanmin, a professor-level senior engineer of the institute, was interviewed by a reporter from the China Industry News. As the most important subject of this major project, “the development of large-scale single-stage crusher and the development of the double tooth roller crusher”, he has another identity—the vice president of Zhongtian Shiming Technology Group Co., Ltd. manager. Special research and development is undertaken by his company.
The results developed by the project led by Han Minmin are mainly used for the crushing of the main raw materials for a new dry process production line of 10,000 tons/day cement clinker. Based on the different properties of limestone and clay materials, as well as high abrasive and viscous mixtures, dual rotor hammer crushers, double tooth roller crushers and high abrasive and viscous mixtures with screen function have been developed. Broken system three (sets) equipment. They all belong to a single crusher with a large crushing ratio and a maximum crushing ratio of up to 1:100. When the material is broken by a crusher, its products meet the needs of the clinker preparation of the 10,000 tons/day cement production line.
Among them, the double rotor single-stage hammer crusher not only has the advantages of small rotor size, light body and low equipment cost under the same production capacity, but also has strong adaptability to moisture-containing materials, and also realizes zero discharge of mineral resources. . "The safety performance of this equipment has a very high level. Even if you enter the iron several times, it will not cause damage to other parts. This is unimaginable on old models or imported models."
Double tooth roller crusher has a wide range of materials that can be broken, can not easily be blocked and bonded, and has high operating rate. The high-abrasive and wet-moist mixture crushing system with a screening function solves the problem of handling such materials at home and abroad for the first time.
The two devices that were developed for the first time not only met the needs of a 10,000-ton/day cement clinker production line, but also had numerous innovations.
The first is the invention of an integral casting forward boring plate and the development of a hollow bearing anvil, which greatly improves the safety, operating rate, and adaptability to the moisture-containing materials of the double-rotor single-stage hammer crusher. Secondly, for the first time in the country, an integral roller skin with taper fit was developed. The safety was very high and the maintenance was convenient. At the same time, an adjustable mud control device was developed, which completely eliminated the problem of the clay plug crusher. Finally, the application of the four-link crusher plate device has opened up a precedent for domestic crushers of this type.
The project's creative application of the device on the device is also a major highlight. According to reports, not only dual-rotor single-stage hammer crusher uses a damping device to improve the safety of the equipment, but also for the first time the hydraulic system and speed measuring device applied to the tooth roller crusher, the crusher feeding automatic adjustment , greatly improving its degree of automation. In addition, the flexible hydrophobic resin was also applied to the tooth roller crusher for the first time, improving the operating rate of the equipment.
Technology reaches international standards
In the 1970s, China began to introduce new dry process technology and host equipment, including crushers, and digest and absorb it. After accumulating experience in use, the Tianjin Cement Industry Design and Research Institute developed a single-stage hammer crusher with completely independent intellectual property rights in 1982, filling the domestic blank at that time. Since then, this crusher special research and development institution has been retained so far, specializing in the development and development of crushers for cement production, which also provides them with a good foundation for the development of these devices.
The development of these equipments of Tianjin Cement Industry Design and Research Institute is based on the absorption of advanced structures of similar models from abroad and the experience of using domestically produced smaller models, and has incorporated designs that meet China's national conditions and meet new requirements for large-scale development. The new concept has completely reached the international level.
It is understood that the European dual-rotor single-stage hammer crusher professional company in the design of similar products, the dumping rake commonly used single purlin transverse full width through the rake structure, wear faster, and vulnerable to the impact of ore And damage. With the wear of the purlin, it is difficult to ensure the product particle size. At the same time, the material requirements for the purlins are also high, making it difficult to manufacture. Bian Hanmin's design team successfully applied the overall casting forward seesaw technology to solve this problem and improve the safety and reliability of the equipment. At the same time, this project successfully developed a new structure of high manganese steel bearing anvil that is convenient for water toughness treatment, and its performance exceeds that of multi-alloy steel bearing anvils of similar foreign products. In addition, the specially designed iron separation chamber at the rear of the housing and the buffer mechanism of the dice adjustment mechanism also make the safety and reliability of the aircraft significantly ahead of similar foreign products.
In addition, the price of these equipment is only one-third to one-half of the imported equipment and has completely replaced imported products in the domestic market. At present, the above-mentioned equipment has already been put into use in four 10000 tons/day and more than 20 considerable cement clinker production lines, and eight (sets) of equipment have been exported to Vietnam and Pakistan.
Three large-scale equipment to achieve industrial applications
The “10,000 tons/day cement dry clinker new dry production process and complete equipment development” project, in addition to the large-scale crushing equipment for cement raw materials developed by Tianjin Cement Industry Design and Research Institute, also includes large-height mechanical conveying equipment and cement kiln pulverized coal metering. With control equipment.
In addition to the largest domestic production of double-rotor hammer crushers and tooth roller crushers for the first time, this project has also successfully developed large-heavy-duty steel wire belt lifters for the first time in China; it has developed patented steel wire tapes and original automatic tape balancing sheets. Tight device, self-developed steel wire tape joint connection technology and special alloy material belt clamps; domestic Coriolis mechanics principle is applied to the powder material measurement field for the first time, independent innovation has been successfully developed based on the principle of Coriolis force scales, special torque sensors And signal conversion device.
The project's technical indicators have reached the international advanced level of similar technology, won the first prize of scientific and technological progress in the building materials industry.
It is understood that after successful development of these technical equipments, it has been put into industrial application. Prior to this, these technical equipments were long-term dependent on imports. At present, this project has become the first choice for China's new or reconstructed cement production line, basically replacing imports and achieving volume export.
According to statistics, as of the end of 2006, a total of 895 sets of high-strength steel wire belt high-efficiency hoists were sold, with a domestic market share of over 95%; and 73 large-scale single-stage crushers and double-tooth roller crushers were sold, with a domestic market share. 100%, the supply of the world ranked second; KXT pulverized coal metering and control system sold 270 sets, accounting for more than 50% of domestic new construction market share.
By the end of 2007, the above three technical products had accumulated production value of 683 million yuan for R&D units, which saved cement companies 165 million U.S. dollars in foreign currency, saved operating expenses 37,756.5 million yuan, and created foreign exchange of 1,120,800 U.S. dollars for the country.
Fourth-generation coolers are more energy efficient
In the clinker burning system of the new dry process cement production line, the cooling machine is the main equipment for the cooling of cement clinker. On May 6th this year, China's first fourth-generation continuous-flow steady-flow cooling machine was delivered from Xuzhou Zhongtian Shiming Technology Group Co., Ltd., marking a new level in the localization of China's new dry process cement technology major equipment. The fourth-generation cooling machine will also be declared next year's National Science and Technology Progress Award.
It is understood that the development of the cooling machine has now gone through four generations of the process, but the overall requirements are the same: high efficiency, energy saving, low consumption, low cost and so on.
The fourth-generation cooling machine has greatly improved the equipment structure and performance, so the promotion and application is also a general trend. It has a unique structure, using a number of proprietary technologies such as air flow control valves, shuttle-type reciprocating push-less boring machines, and four-bar linkage drive systems, to ensure that coolers improve heat recovery efficiency over third-generation coolers3 %~5%, the clinker cooling efficiency is greatly improved, the cooling fan power consumption is reduced by 20%, the service life of the boring machine is doubled, and it has high operating rate, low wear rate, easy maintenance and maintenance, compact structure of the whole machine, saving investment, etc. Significantly Features. Compared with the third-generation grate coolers, taking a 5,000-ton/day production line as an example, 3,600 tons of standard coal can be saved each year, and 2.3 million kilowatt-hours of electricity can be saved annually. In addition, due to the absence of a funnel in the lower part of the equipment, the amount of work required for the pit of the cooling machine can also be significantly reduced, saving a lot of investment in civil engineering and steel structures.
Industry experts believe that the introduction of the fourth-generation cooler will further meet the requirements of customers at home and abroad to build energy-saving, high-yield, and high-efficiency cement production lines, improve the international competitiveness of China's cement industry technology and equipment, and save energy and reduce emissions for China's cement industry. "Outgoing" strategy contributes to the smooth implementation.
China Cement Association Comments: The development of China's new dry process cement has been more than 30 years. From 700 tons of Nissan to 10,000 tons of Nissan, the expansion of production scale is a process of constant technological innovation. It not only embodies the hard work of cement technical engineers, but also devotes itself to the hard work of the electromechanical processing industry. It is also inseparable from the leadership of the former National Building Materials Bureau. And the long-term support of the older generation of cement industry leaders.
Energy-saving, energy-saving, emission reduction, recycling economy, and sustainable development are the only way out for China's cement industry. The development of new dry-process cement is a need for structural adjustment in the cement industry. The scale of cement companies determines the market competitiveness of enterprises and also reflects the profitability of the industry. The large scale of cement equipment is not only a research and development capability, but also requires the support of processing capacity and management capabilities. The completion of the project of “New Type Dry Production Process and Complete Equipment Development for Cement Production of 10,000 tons/day” indicates that China's cement engineering technology has reached the world's advanced level. At present, 4 of the million tons of cement production lines in the world are shipped in China. Moreover, China's 10,000-ton cement production line is also exported to foreign countries. The research and development and application of this project is of great significance for realizing the adjustment of China's cement structure, saving energy and reducing consumption, building a resource-saving, environment-friendly society and the sustainable development of the cement industry.
10,000 tons of cement production line in China's concentrated consumption of cement products, as long as the mine resources are guaranteed, the market prospects for equipment is good. However, in most regions, the production lines of 5,000 tons and 3,000 tons of Nissan will continue to dominate. Large equipment has certain restrictions on transportation. For investors, there is a trade-off between the technical economy of investment and the return on investment. The 10,000-ton cement production line is mainly suitable in the south.
The development of technology is endless, and the advance research and development carried out by international counterparts is the lesson we want to supplement. At present, we are only absorbing and transforming. The completion of this project does not mean that we are ahead of us. China's cement industry must continue to work hard, and technological progress will never end.
It has been an important part of the work of the China Cement Association to promote the technological progress of the industry. As for the project of “Daily Production of 10,000 tons of cement clinker for new dry process production and complete sets of equipment”, the association has provided active support for the project and product application. The two main undertaking units of the project are members of the association. Serving the member units and opening the market for new products are also the obligations of the association. The project includes twin-rotor hammer crusher and tooth roller crusher, high-strength steel wire belt efficient bucket elevator, Coriolis force pulverized coal metering system and other sub-items R&D projects. The association and the China Building Materials Federation have organized Identification of special achievements.

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