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任务书 题目名称2000t/d水泥回转窑烟气除尘工程设计学生学院环境科学与工程学院专业班级姓 名学 号一、毕业设计（论文）的内容水泥回转窑烟气除尘工程设计，包括袋式除尘器的工艺原理与结构、水泥回转窑烟气除尘工艺、主体设备选型和非标准设备设计，管道输送系统设计及工程投资概算等。二、毕业设计（论文）的要求与数据废气处理量：毕业实习收集，或者“按产排污系数手册”；废气成分：毕业实习收集，或者“按产排污系数手册”；毕业实习10天以上；实习报告（含资料调研报告）10000字以上； 毕业设计说明书30000字以上；绘制工程设计图纸8张（A4）以上。三、毕业设计（论文）应完成的工作查阅和翻译文献资料；参与毕业实习并编写实习报告；编写毕业设计说明书；进行工程概算和运行可行性分析；绘制工程设计图纸。序号设计（论文）各阶段内容起止日期1参与毕业实习3月15日4月12日2编写实习报告、查阅和翻译文献资料4月134月25日3研究设计方案，进行设计的有关计算4月26日5月10日4编写毕业设计说明书5月11日5月25日5进行工程概算和运行可行性分析5月26日5月29日6绘制工程设计图纸5月30日6月8日7答辩准备及答辩6月9日6月12日四、毕业设计（论文）进程安排五、应收集的资料及主要参考文献1. 王志魁主编 . 化工原理 .第二版.北京：化学工业出版社，1998.10 2. 赫吉明 马广大主编 . 大气污染控制工程. 第二版.北京：高等教育出版社，20023. 贺匡国主编.化工容器及设备简明设计手册.化学工业出版社，19894. 黄学敏.张承中主编. 大气污染控制工程实践教程.北京：化学工业出版社. 2003.95. 立本英机.安部郁夫（日）主编.高尚愚译编. 活性炭的应用技术其维持管理及存在问题.南京：东南大学出版社，2002.76. 林肇信主编.大气污染控制工程.高等教育出版社.1991.57. 全燮.杨凤林主编. 环境工程计算手册.中国石化出版社.2003.68. 吴忠标主编 . 实用环境工程手册大气污染控制工程 化学工业出版社. 2001.99. 姜安玺主编. 空气污染控制 .北京：化学工业出版社. 2003 10. 朗晓珍. 杨毅宏主编. 冶金环境保护及三废治理技术. 东北大学出版社. 2002 11. 童志权等主编. 工业废气污染控制与利用. 北京：化学工业出版社，1988 12. 王绍文.张殿印.徐世勤.董保澍主编. 环保设备材料手册.冶金工业出版社 2000.9 13. 朱世勇，环境与工业气体净化技术，化学工业出版社，200114. 李光超，大气污染控制技术，化学工业出版社，200215. L.Ekman.LIFAC-经济有效的脱硫方法.芬兰：Fortum Engineering Ltd.16. 唐敬麟，张禄虎编. 除尘装置系统及设备设计选用手册化学工业出版社.200417. 给水排水设计手册 （第11卷），中国建筑工业出版社，1986.18. 赵毅，李守信，有害气体控制工程，化学工业出版社，2001. 19. 陈常贵、曾敏静、刘国雄等编，化工原理，天津科学技术出版社，2002 20. Licht,WAir Pollution Control Engineering.Publisher,New York,NY(US);Marcel Dekker,Inc.System Entry Date:2001 May 13.21. Dry Removal of Gaseous Pollutants from Flue Gases with the GFB(FGD by CFB).Lurgi Report,Germany,1990.22. 刘天齐主编，三废处理工程技术手册：废气卷，北京：化学工业出版社 1999.5发出任务书日期：20xx年3月10日指导教师签名：预计完成日期：20xx年6月12日专业负责人签章：主管院长签章：2Energy auditing and recovery for dry type cement rotary kiln systemsA case studyAbstractCement production has been one of the most energy intensive industries in the world. In order to produce clinker, rotary kilns are widely used in cement plants. This paper deals with the energy audit analysis of a dry type rotary kiln system working in a cement plant in Turkey. The kiln has a capacity of 600 ton-clinker per day. It was found that about 40% of the total input energy was being lost through hot flue gas (19.15%), cooler stack (5.61%) and kiln shell (15.11% convection plus radiation). Some possible ways to recover the heat losses are also introduced and discussed. Findings showed that approximately 15.6% of the total input energy (4 MW) could be recovered.Keywords: Cement plant; Rotary kiln; Energy audit; Heat balance; Heat recovery1. IntroductionCement production is an energy intensive process, consuming about 4 GJ per ton of cement product. Theoretically, producing one ton of clinker requires a minimum 1.6 GJ heat 1. However, in fact, the average specific energy consumption is about 2.95 GJ per ton of cement produced for well-equipped advanced kilns, while in some countries, the consumption exceeds 5 GJ/ton. For example, Chinese key plants produce clinker at an average energy consumption of 5.4 GJ/ton 2. The energy audit has emerged as one of the most effective procedures for a successful energy management program 3. The main aim of energy audits is to provide an accurate account of energy consumption and energy use analysis of different components and to reveal the detailed information needed for determining the possible opportunities for energy conservation. Waste heat recovery from hot gases 4 and hot kiln surfaces 5 in a kiln system are known as potential ways to improve overall kiln efficiency. However, it is still fairly difficult to find a detailed thermal analysis of rotary kiln systems in the open literature. This paper focuses on the energy audit of a horizontal rotary kiln system, which has been using in the Van Cement Plant in Turkey. A detailed thermodynamic analysis of the kiln system is first given, and then, possible approaches of heat recovery from some major heat loss sources are discussed.2. Process description and data gatheringRotary kilns are refractory lined tubes with a diameter up to 6 m. They are generally inclined at an angle of 33.5o, and their rotational speeds lie within 12rpm. Cyclone type pre-heaters are widely used to pre-heat the raw material before it enters the kiln intake. In a typical dry rotary kiln system, pre-calcination gets started in the pre-heaters, and approximately one third of the raw material would be pre-calcined at the end of pre-heating. The temperature of the pre-heated material would be of the order of 850 oC. The raw material passes through the rotary kiln towards the flame. In the calcination zone (700900 oC), calcinations, as well as an initial combination of alumina, ferric oxide and silica with lime, take place. Between 900 and 1200 oC, the clinker component, 2CaO SiO2, forms. Then, the other component, 3CaOSiO2, forms in a subsequent zone in which the temperature rises to 1250 oC. During the cooling stage, the molten phase, 3CaOAl2O3, forms, and if the cooling is slow, alite may dissolve back into the liquid phase and appear as secondary belite 6. Fast cooling of the product (clinker) enables heat recovery from the clinker and improves the product quality.The data taken from the Van Cement Plant have been collected over a long period of time when the first author was a process engineer in that plant. The plant uses a dry process with a series of cyclone type pre-heaters and an incline-kiln. The kiln is 3.60 m in diameter and 50 m long. The average daily production capacity is 600 ton of clinker, and the specific energy consumption has been estimated to be 3.68 GJ/ton-clinker. A large number of measurements have been taken during 2yr, and averaged values are employed in this paper. The raw material and clinker compositions are given in Table 1. The rotary kiln system considered for the energy audit is schematically shown in Fig. 1. The control volume for the system includes the pre-heaters group, rotary kiln and cooler. The streams to and from the control volume and all measurements are indicated in the same figure.3. Energy auditing and heat recovery3.1. Mass balanceThe average compositions for dried coal and pre-heater exhaust gas are shown in Fig. 2. Based on the coal composition, the net heat value has been found to be 30,600 kJ/kg-coal.It is usually more convenient to define mass/energy data per kg clinker produced per unit time.The mass balance of the kiln system is summarized in Fig. 3. All gas streams are assumed to be ideal gases at the given temperatures.3.2. Energy balanceIn order to analyze the kiln system thermodynamically, the following assumptions are made:1. Steady state working conditions.2. The change in the ambient temperature is neglected.3. Cold air leakage into the system is negligible.4. Raw material and coal compositions do not change.5. Averaged kiln surface temperatures do not change.Based on the collected data, an energy balance is applied to the kiln system. The physical properties and equations can be found in Perays handbook 7. The reference enthalpy is considered to be zero at 0 oC for the calculations. The complete energy balance for the system is shown in Table 2. It is clear from Table 2 that the total energy used in the process is 3686 kJ/kg clinker, and the main heat source is the coal, giving a total heat of 3519 kJ/kg-clinker (95.47%). Also, the energy balance given in Table 2 indicates relatively good consistency between the total heat input and total heat output. Since most of the heat loss sources have been considered, there is only a 273 kJ/kg-clinker of energy difference from the input heat. This difference is nearly 7% of the total input energy and can be attributed to the assumptions and nature of data. The distribution of heat losses to the individual components exhibits reasonably good agreement with some other key plants reported in the literature 2,5,7.3.3. Heat recovery from the kiln systemThe overall system efficiency can be defined bywhich can be regarded as relatively low. Some kiln systems operating at full capacity would declare an efficiency of 55% based on the current dry process methodology. The overall efficiency of the kiln system can be improved by recovering some of the heat losses. The recovered heat energy can then be used for several purposes, such as electricity generation and preparationT. Engin, V. Ari / Energy Conversion and Management 46 (2005) 551562 557of hot water. There are a few major heat loss sources that would be considered for heat recovery. These are heat losses by: (1) kiln exhaust gas (19.15%), (2) hot air from cooler stack (5.61%) and (3) radiation from kiln surfaces (10.47%). In the following section, we discuss some possible ways for recovering this wasted heat energy.3.3.1. The use of waste heat recovery steam generator (WHRSG)There are opportunities that exist within the plant to capture the heat that would otherwise be wasted to the environment and utilize this heat to generate electricity. The most accessible and, in turn, the most cost effective waste heat losses available are the clinker cooler discharge and the kiln exhaust gas. The exhaust gas from the kilns is, on average, 315 oC, and the temperature of the air discharged from the cooler stack is 215 oC. Both streams would be directed through a waste heat recovery steam generator (WHRSG), and the available energy is transferred to water via the WHRSG. The schematic of a typical WHRSG cycle is shown in Fig. 4. The available waste energy is such that steam would be generated. This steam would then be used to power a steam turbine driven electrical generator. The electricity generated would offset a portion of the purchased electricity, thereby reducing the electrical demand.In order to determine the size of the generator, the available energy from the gas streams must be found. Once this is determined, an approximation of the steaming rate for a specified pressure can be found. The steaming rate and pressure will determine the size of the generator. The following calculations were used to find the size of the generator.where is the WHRSG efficiency. Because of various losses and inefficiencies inherent in the transfer of energy from the gas stream to the water circulating within the WHRSG, not all of the available energy will be transferred.T. Engin, V. Ari / Energy Conversion and Management 46 (2005) 551562 557A reasonable estimate on the efficiency of the WHSRG must be made. We assume an overall efficiency of 85% for the steam generator. As the gas passes through the WHRSG, energy will be transferred and the gas temperature will drop. Targeting a pressure of 8 bars at the turbine inlet, the minimum stream temperature at the WHRSGs exit would be higher than the corresponding saturation temperature, which is roughly 170 oC. As a limiting case, we assume the exit temperatures to be 170 oC. After exiting the WHRSG, the energy of those streams can be recovered by using a compact heat exchanger. Hence, the final temperature can be reduced as low as possible, which might be limited by the acid dew point temperature of the stream. According to the final temperatures of both streams, the final enthalpies have been calculated to be hair = 173 kJ/kg, and heg = 175 kJ/kg. Therefore, the available heat energy would be:Therefore, the energy that would be transferred through the WHSRG isThe next step is to find a steam turbine generator set that can utilize this energy. Since a steam turbine is a rotating piece of machinery, if properly maintained and supplied with a clean supply of dry steam, the turbine should last for a significant period of time. Considering a turbine pressure of 8 bars and a condenser pressure of 10 kPa, it can be shown that the net power, which would be obtained from the turbine, is almost 1000 kW. If we assume that the useful power generated is 1000 kW, then the anticipated savings will be based on the load reduction of 1000 kW. Assuming 8000 h of usage, we find The average unit price of electricity can be taken as 0.07 USD/kWh, and therefore, the anticipated cost savings would beIf we assume that labor and maintenance costs averaged out to 20,000 USD annually, the savings becomes 540,000 USD/year.The cost associated with implementation of this additional system would be the purchase price of the necessary equipment and its installation. An additional cost will be the required maintenance of the power generation unit. For the whole system shown in Fig. 4, based on our calculations, we were able to determine a budget estimation between 700,000 and 750,000 USD, including shipping and installation. Hence, we can make a rough estimate for a simple pay back period:The energy savings by using a WHSRG system would also result in an improvement in the overall system efficiency. It should be noted that these calculations reflect a rough estimation and may vary depending upon plant conditions and other economic factors.3.3.2. Use of waste heat to pre-heat the raw materialOne of the most effective methods of recovering waste heat in cement plants would be to preheat the raw material before the clinkering process. Directing gas streams into the raw material just before the grinding mill generally does this. This would lead to a more efficient grinding of the raw material in addition to increasing its temperature. However, in most plants, the fresh raw material taken from the mill is not directly sent to the kiln, and therefore, the temperature increase of the raw material does not generally make sense because it will be stored in silos for a while before entering the clinkering process. On the other hand, some plants may have only kiln systems rather than grinding systems. In such cases, this may not be possible unless some additional modifications are made in the plant.There is a grinding mill in the plant considered in this study, and the following calculations are made to show how much energy could be saved through pre-heating the raw material. The main advantage of the pre-heating of raw material in the mill is to dry the material, since it is heavily moist in nature. For the plant considered, the moisture content of the raw material was about 6.78%, which indicates a mass flow rate of water of 0.7845 kg/s (0.113 kg/kg-clinker) coming into the mill. Mixing the two main hot gas streams would lead to a single gas flow at about 280 oC, as shown in Fig. 5. Applying the conservation of mass principle and conservation of total energy law for the mill (ignoring heat losses) results in an increase of temperature of the raw material by 85 oC, while the gas stream cools down to 150 oC. It is clear that the majority of the useful energy must be used to heat the water from 15 to 100 oC, and to vaporize it at this temperature completely.A basic energy balance for the mill system would giveThe related enthalpies are shown in Fig. 5. Therefore, we can writeT. Engin, V. Ari / Energy Conversion and Management 46 (2005) 551562 5593.3.3. Heat recovery from kiln surfaceThe hot kiln surface is another significant heat loss source, and the heat loss through convection and radiation dictates a waste energy of 15.11% of the input energy. On the other hand, the use of a secondary shell on the kiln surface can significantly reduce this heat loss. Since the kiln surface needs to be frequently observed by the operator so as to see any local burning on the surface due to loss of refractory inside the kiln, we would not consider insulating the kiln surface. The basic principle of the secondary shell is shown in Fig. 6.For the current rotary kiln, Rkiln =3.6 m, and a radius of Rshell = 4 m can be considered. Since the distance between the two surfaces is relatively small (40 cm), a realistic estimation for the temperature of the secondary shell can be made. We assume T2 = 290 oC = 563 K. We would consider stainless steel for the material of the secondary shell since it has relatively low surface emissivity and thermal conductivity. The heat transfer rate by radiation is then calculated using the following equation 8:This heat loss is to be transferred through the insulation on the secondary shell. Therefore, assuming a reasonable temperature for the outer surface of the insulation, we can determine the required thickness of insulation. For glass wool insulation, the thermal conductivity is taken as 0.05 W/mK. Therefore, the resistance of the insulation layer would beT. Engin, V. Ari / Energy Conversion and Management 46 (2005) 551562 561It should be noted that when the secondary shell is added onto the kiln surface, the convective heat transfer would presumably become insignificant. This is because of the fact that the temperature gradient in the gap would be relatively very low, e.g., 0.45 oC/cm. Therefore, the total energy savings due to the secondary shell would befrom the radiation heat transfer andfrom the convective heat transfer. Therefore, we can safely conclude that the use of a secondary shell on the current kiln surface would save at least 3 MW, which is 11.7% of the total input energy. This energy saving would result in a considerable reduction of fuel consumption (almost 12%) of the kiln system, and the overall system efficiency would increase by approximately 56%.4. ConclusionsA detailed energy audit analysis, which can be directly applied to any dry kiln system, has been made for a specific key cement plant. The distribution of the input heat energy to the system components showed good agreement between the total input and output energy and gave significant insights about the reasons for the low overall system efficiency. According to the results obtained, the system efficiency is 48.7%. The major heat loss sources have been determined as kiln exhaust (19.15% of total input), cooler exhaust (5.61% of total input) and combined radiative and convective heat transfer from kiln surfaces (15.11% of total input). For the first two losses, a conventional WHRSG system is proposed. Calculations showed that 1 MW of energy could be recovered. For the kiln surface, a secondary shell system has been proposed and designed. It is believed that the use of this system would lead to 3 MW of energy saving from the kiln surface. Hence, the total saving for the whole system has been estimated to be nearly 4 MW, which indicates an energy recovery of 15.6% of the total input energy. The pay back period for the two systems is expected to be less than 1.5 yr.References1 Liu F, Ross M, Wang S. Energy efficiency of Chinas cement industry. Energy 1995;20(7):66981.2 Khurana S, Banerjee R, Gaitonde U. Energy balance and cogeneration for cement plant. Appl Therm Eng2002;22:48594.T. Engin, V. Ari / Energy Conversion and Management 46 (2005) 551562 5613 Pahuja A. Energy auditing and monitoring in the cement industry. Energy Conservation and Environmental Controlin Cement Industry, vol. 2, Part 2, Published by Akademia Books International, ISBN: 81-85522-05-7, 1996. p. 67094.4 Kamal K. Energy efficiency improvement in the cement industry. Seminar on Energy Efficiency, organized byASSOCHAM-India and RMA-USA, January 1997.5 Engin T. Thermal analysis of rotary kilns used in cement plants. First Mechanical Engineering Congress(MAMKON97), Istanbul Technical University, TURKIYE, 46 June 1997, p. 2935 in Turkish.6 Kaantee U, Zevenhoven R, Backman R, Hupa M. Cement manufacturing using alternative fuels and advantages ofprocess modelling. Presented at R2002 Recovery, Recycling, Re-Integration, Geneva, Switzerland, Available from:http:/www.R2002.com, 1215 February 2002.7 Peray KE. Cement manufacturers handbook. New York, NY: Chemical Publishing Co., Inc.; 1979.8 Cengel YA. Heat transferA practical approach. 2nd ed. New York, NY: McGraw-Hill; 2003.译文干型的水泥回转窑系统的能量验核和补救 一个专题研究文摘水泥生产是世界上其中一最能源消耗量大的产业。 为了生产粉煤渣，回转炉广泛应用在水泥厂。 本文对在土耳其的一个水泥厂运作的一个干型的回转窑系统的能源使用审计分析。 这种窑有每天600的吨粉煤渣的容量。 发现大约40%总输入能量通过热的废气(19.15%)，冷却器堆 (5.61%)和窑壳(15.11%传送加上辐射)的渠道损失能量。一些可能恢复热耗的方式也有介绍和被谈论。 研究结果表示，大约15.6%总输入能量(4兆瓦)可能被恢复。关键词：水泥厂，回转窑，能量审计，热量平衡，热量恢复目录1介绍12过程描述和数据收集23.能量审计和热量恢复43.1 质量平衡43.2 能量平衡43.3 从回转窑中的热能恢复53.3.1余热回收蒸汽发生器的使用(WHRSG)83.3.2利用废热预先加热原材料93.3.3从窑表面的热能恢复104. 总结121介绍水泥生产是一个能源消耗量大的过程，每吨水泥产品消耗大约每吨4 GJ。 理论上，生产一吨粉煤渣要求极小的1.6 GJ热1。 然而，实际上，平均具体能源消耗是大约装备精良的先进窑生产的水泥每吨消耗大约2.95 GJ，而在某些国家，消耗量超出5 GJ/ton。 例如，中国主要厂家生产粉煤渣在5.4 GJ/ton的平均能量消耗量2。 能源使用审计已经形成了作为其中一个成功的能量消耗监控节目的最有效的做法3。能源使用审计的主要目标将提供对不同的组分的能源消耗和能量利用分析一个准确帐户和暴露为确定能源节约的可能的机会需要的详细信息。 从热的气体的余热回收4和热的窑表面在窑系统叫作潜在的方式改进整体窑效率5。 然而，对在对外开放的文献中找到对回转炉系统的一个详细的热分析仍然是相当难的。 本文集中于一个水平的回转炉系统的能源使用审计，这个已经使用在土耳其的Van水泥厂。 对窑系统的详细的热力学分析是首先要假定的，然后，谈论一些主要热耗源头的热补救的可行的方法。2过程描述和数据收集回转窑是一个直径等于6 m的具有线纹的耐火管。 他们通常倾斜有一个角度33.5o，并且他们旋转的速度在12rpm之间。 在它进入窑入口之前，旋风类型预热器是广泛用于预先加热原材料。 在一个典型的干燥回转窑系统，前锻烧在预热器开始，并且原材料的大约三分之一将前在预先加热的结尾被锻烧。被预先加热的材料的温度是等级850 oC。 原材料穿过往火焰的回转窑。 在锻烧区域(700900 oC)，锻烧，并且铝土的一个最初的组合，氧化铁、硅土与石灰发生反应。 在900和1200 oC之间，粉煤渣组分， 2CaOSiO2的形式。 然后，在一个温度升高到1250 oC的随后区域，产生另一个组分， 3CaO SiO2的形式。在冷却的阶段期间，溶解的阶段， 3CaO Al2O3 的形式，如果冷却是慢的，铝铁岩也许溶化回到液体阶段和作为次要水泥石的形式出现6。产品(粉煤渣) 的快速冷却使能从粉煤渣的热能恢复并且改进产品质量。当第一位作者是那工厂的一位工艺工程师，从Van水泥厂收集了收集了一段长时期的数据。那工厂使用一系列的旋风类型预热器和倾斜窑的一个干式法。 窑是直径为3.60 m和50 m长。 平均日产量容量是600吨粉煤渣，并且具体能源消耗估计有3.68 GJ/ton粉煤渣。在2年期间，很多测量的数量被采取了，并且平均值在本文中医药使用。 原材料和粉煤渣构成在表2.1被给出。 为能源使用审计考虑的回转窑系统在图2.1概要地显示。 系统的控制体积包括预热器组、回转窑和致冷机。 在同一个图表明了控制体积的来源来去向和所有测量法。表2.1 能量转化和处理原材料和粉煤渣的成分和它们的百分比成分 原材料(%) 粉煤渣(%)SiO2 13.55 20.55Al2O2 4.10 5.98Fe2O3 2.60 4.08 CaO 40.74 64.58 MgO 2.07 2.81SO3 0.56 1.30 K2O 0.30 0.50 Na2O 0.08 0.20H2O 0.5 -有机物 0.9 -燃烧损失 34.6 - 总共 100 100图2.1 窑系统的容量控制、各种蒸气和其构成3.能量审计和热量恢复31 质量平衡干煤炭和预热器废气的平均构成显示的图3.1，根据煤炭构成,净热值为30,600 kJ/kg煤炭。 它通常是更加方便定义每个单位时间被生产的kg粉煤渣的质量或能量数据。窑系统的质量平衡被总结于图3.2。 所有气流假设是在特定温度的理想气体。3.2 能量平衡为了在热力学上分析窑系统，设定以下假定：1. 稳定工作环境。2. 周围温度的变化被忽略。3. 冷空气漏进到系统里是微不足道的。4. 原材料和煤炭构成不改变。5. 平均的窑表面温度不改变。图3.1 (a)煤的构成,(b)预加热的废气的构成(按重量比)窑系统输入:kg/kg-粉煤渣 输出:kg/kg-粉煤渣1.667 原材料 预加热的废气 2.094 渣块 1.0002.300 冷却的气体 冷却机的灰尘 0.006 冷却机的热气 0.9400.115 煤 预加热的灰尘 0.042 图3.2 回转窑的质量平衡在收集的数据的基础上，能量平衡被应用于窑系统。物理属性和方程式可以在Peray的手册7找到。 在演算中,在0 oC时参考焓被认为是零。 系统的全部的能量平衡在表3.1显示。 从表3.1清楚得了解到在进程中的总能量是3686 kJ/kg粉煤渣，并且主要热源是煤炭，具有3519 kJ/kg粉煤渣(95.47%)的总热能。并且，在表3.1中给予的能量平衡相关地指出在总热量输入和总热量输出之间的最佳密度。 因为考虑了大多数的热耗来源，有仅273 kJ/kg粉煤渣的能量区别于输入热量值。 这个区别是几乎7%总输入能量，并且可以归因于数据的假设和种类。 对各自的陈列组分的热量损耗的区别与文献报告中的其他主要工厂的相当的一致2,5,7。3.3 从回转窑中的热能恢复全部的系统效率能被定义为=Q6/Qtotal input =1795/3686 =0.487或者 48.7%,被认为是相当地低的。一般情况下烟气温度400500 ，相当长的时间达到800 ，在非正常操作情况下，烟气温度可达1 000。目前一些地方采用往烟气里渗入冷风的方法，或者采用蛇形管外壁冷却的方法降低烟气的温度。前者将加大烟气的体积，从而加大烟气的处理量，并且将增加烟气净化的设备费用及处理费用。高温烟气含有大量的能量，在考虑净化烟气的同时，考虑到将能量取出，用于生产和生活，实现污染源的综合治理。一些满负载运行的窑炉系统宣称根据当前干式法方法学将能达到高至55%的效率。 窑炉系统的综合效率可以经过恢复某些损耗的热量而得到大大地提高。然后，恢复的热能可能使用于几个方面，例如电力生产和生产热水的准备。有一些个别主要热耗来源将会因为热能恢复所考虑到。 这些热耗为： (1)干燥废气(19.15%)， (2)来自冷却机的热气流(5.61%)和(3)从窑表面的热传递(10.47%)。 在以下部分，我们将谈论这被浪费的热能量的可恢复的一些可能的方式。表3.1 窑系统的综合能量守衡3.3.1余热回收蒸汽发生器的使用(WHRSG)在工厂内，夺取对于环境来说是被浪费的热和运用这些热能发电的机会是存在的。 可利用最容易受影响的，并且，反过来，最有效的废热的损失是粉煤渣冷却机的放电和窑炉废气。 从窑炉排出来的废气是，平均 315 oC，并且从冷却机释放的空气的温度是215 oC。两种液体通过一个余热回收蒸汽发生器(WHRSG)将被指挥，并且有效能通过WHRSG转移到水。 一个典型的WHRSG周期的概要在图3.3 可利用的废物能源像这样蒸汽一样将会产生。 这蒸汽然后将被用于供给蒸汽机被驾驶的电子发电器动力。 发的电将抵销一部分要购买的电，从而减少电量需求。为了确定发电器的大小，必须找出蒸汽的有效能。 一旦这个确定，可以找到通过蒸汽的比率略计指定的压力的近似值。 通入蒸汽比率和压力将确定发电器的大小。 以下演算被用于确定发电器的大小。QWHRSG =Qavailable其中，是WHRSG的功率。由于各种各样的损失和固有的无效能在通在WHRSG能量从气体对水流转移，不是全部有效能都能转移。图3.3 典型的WHRSG应用程序的工艺流程在WHSRG的效率方面的一个合理的估计必须完成。 我们假设蒸汽发生器的综合效率为85%。 因为气体穿过WHRSG，将转移能量，并且气体温度将会下降。 瞄准在涡轮入口的8个齿龈的压力，极小的气流温度在WHRSG的出口高于对应的饱和温度，是大致170 oC。 作为一种限制情况，我们假设出口温度是170 oC。在退出WHRSG以后，通过使用紧凑热转换器，那些气流的能量可以恢复。 因此，最后的温度可以降得尽可能低，也许由气流的酸露点温度限制。 根据两气流最后的温度，最后的焓被计算是hair = 173 kJ/kg和heg = 175 kJ/kg。 所以，可利用的热能是：Qavailable = meg（heg1heg2）mair（hair1hair2）mcliQavailable =2.094（337175）0.94（220173）6.9442662kW所以，通过WHSRG能被转移的能量是：QWHSRG = 0.85 2662 =2263 kW下一个步骤将找出可能运用这能量的蒸汽机发生器装置。 因为蒸汽机是一个转动