国际上水泥生产能耗的最佳实践值

1、国际上水泥生产能耗的最佳实践值International best practice values of energy consumption for cement p roductionFor the international best practices at each stage of production, data were gathered from public literature sources, plants, and vendors of equip ment. These data and calculations are described below.各个生产过程

2、的国际最佳实践值是按照公布发表的各种文献资料，以 及水泥企业和设备供应商提供的数据确定的。下面来介绍这些数据及其运 算过程。Raw materials and fuel preparation生料和燃料制备Energy used in preparing the raw material consists of preblending (pr ehomogenization and proportioning), crushing, grinding and drying (if nece ssary) the raw meal which is mostly limestone. All m

3、aterials are then ho mogenized before entering the kiln. Solid fuels input to the kiln must als o be crushed, ground, and dried. Best practice for raw materials preparati on is based on the use of alongitudinal preblending store with either bridge scraper or bucket wh eel reclaimer or a circular pre

4、blending store with bridge scraper reclaimer for preblending (prehomogenization and proportioning) at 0.5 kWh/t raw meal, a gyratory crusher at 0.38 kWh/t raw meal, an integrated vertical r oller mill system with four grinding rollers and a high-efficiency separator at 11.45 kWh/t raw meal for grind

5、ing, and a gravity (multi-outlet silo) d ry system at 0.10 kWh/t raw meal for homogenization. Based on the abo ve values, the overall best practice value for raw materials preparation is 12.05 kWh/t raw material. Ideally this value should take into account the differences in moisture content of the

6、raw materials as well as the hardne ss of the limestone. Higher moisture content requires more energy for dry ing and harder limestone requires more crushing and grinding energy. If d rying is required, best practice is to install a preheater to dry the raw ma terials, which decreasesthe efficiency

7、of the kiln. For BEST Cement, it i s assumed that pre-heating of wet raw materials is negligible and does no t decrease the efficiency of the kiln.生料制备的能耗包括生料 （要紧是石灰石） 的预混合（预均化和配料）、 破裂、粉磨和烘干（如果需要的话） 。所有物料在入窑之前都要通过充分的 均化。入窑的固体燃料也要先通过破裂、粉磨和烘干。生料制备的最佳实 践值运算依据如下：预混合采纳带桥式刮板式取料机或斗轮式取料机的纵 向预均化堆场，或者带桥式刮板式取料

8、机的环形预均化堆场（电耗 0.5kWh /t 生料）；破裂采纳转子破裂机（电耗 0.38kWh/t 生料）；生料粉磨采纳带高 效选粉机和四个辊子的立磨系统 （电耗 11.45kWh/t 生料）；均化采纳重力式 （多出口筒仓）烘干系统（电耗 0.10kWh/t 生料）。综合以上能耗数值，生 料制备的最佳总能耗为 12.05kWh/t 生料。理论上，该能耗值还应考虑生料 水分和石灰石硬度的阻碍。水分越大则烘干能耗越多，石灰石硬度越高则 破裂和粉磨能耗越多。如果原料需要烘干，则最佳的措施是安装一个预热 器，尽管它会降低窑的热效率。“ BEST Ceme n”假设烘干湿原料的能耗能 够忽略不计，因此没

9、有降低窑系统的热效率。Solid fuel preparation also depends on the moisture content of the fuel.It is assumed that only coal needs to be dried and ground and that th e energy required for drying or grinding of other materials is insignificantor unnecessary.Best practice is to use the waste heat from the kiln sys

10、tem,for example, the clinker cooler （if available） to dry the coal. Best pr actice using an MPS vertical roller mill is 10-36 kWh/t anthracite, 6-12 k Wh/t pit coal, 8-19 kWh/t lignite, and 7-17 kWh/t petcoke or using a bo wl mill is 10-18 kWh/t product. Based on the above, it is assumed that b est

11、practice for solid fuel preparation is 10 kWh/t product.固体燃料制备的能耗也与燃料的水分有关。“ BEST Ceme nt”假设只有 煤需要烘干和粉磨，其他物料的烘干和粉磨能耗可忽略不计。烘干煤粉的 最佳措施是利用窑系统（如熟料冷却机）的废热做烘干热源。煤粉磨的最 佳措施是采纳MPS立磨(电耗为10-36kWh/t无烟煤，6-12kWh/t烟煤，8- 19kWh/t褐煤，7-17kWh/t石油焦)，或碗磨(电耗为10-18kWh/t产品)。综 合以上能耗数值，燃料制备的最佳总能耗为 10kWh/t 产品。-Additives prepar

12、ation混合材制备In addition to clinker, some plants use additives in the final cement product. While this reduces the most energy intensive stage of production (clinker making), as well as the carbonation process which produces addi tional CO2 as a product of the reaction, some additives require additiona

13、l electricity for blending and grinding (such as fly ash, slags and pozzola ns) and/or additional fuel for drying (such as blast furnace and other slag s).除了熟料以外，一些水泥企业还在水泥终产品中添加混合材。该措施 在减少熟料生产能耗以及 CO2 排放量的同时，需要增加混合材的混合与粉 磨电耗(如粉煤灰、矿渣和火山灰)以及烘干用的燃料消耗(如高炉矿渣 和其他矿渣)。Additional requirements from use of ad

14、ditives are based on the differ ences between blending and grinding Portland cement (5% additives) and other types of cement (up to 65% additives). Portland Cement typically re quires about 55 kWh/t for clinker grinding, while fly ash cement (with 2 5% fly ash) typically requires 60 kWh/t and blast

15、furnace slag cement (w ith 65% slag) 80 kWh/t (these are typical grinding numbers only used to determine the additional grinding energy required by additives, not best pr actice; for best practice refer to data below in cement grinding section). It is assumed that only fly ash, blast furnace and oth

16、er slags and natural pozzolans need additional energy. Based on the data above, fly ash will r equire an additional 20 kWh/t of fly ash and slags will require an additio nal 38 kWh/t of slag. It is assumed that natural pozzolans have requireme nts similar to fly ash. These data are used to calculate

17、 cement grinding r equirements. For additives which are dried, best practice requires 0.75 GJ/ t (26 kgce/t) of additive. Generally, only blast furnace and other slags ar e dried. Those additives that need to be dried (the default is all slags, alt hough the user can enter this data as well in the p

18、roduction input sheet) best practice requires an additional 0.75 GJ/t (26 kgce/t) of additive.按照硅酸盐水泥( 5混合材)和其他类型水泥(混合材配比最高达65)在混合和粉磨方面的差不，添加混合材会增加额外的电耗。硅酸盐水 泥的熟料粉磨电耗一样为 55kWh/t ，而粉煤灰水泥(含 25粉煤灰)的粉 磨电耗一样为 60 kWh/t ，高炉矿渣水泥(含 65矿渣)的粉磨电耗一样为 80 kWh/t (这些能耗数值是掺加混合材的一样能耗水平，不是最佳能耗水 平；最佳能耗水平可参考下文的水泥粉磨部分)。“ B

19、EST Ceme nt”假设只 有粉煤灰、高炉矿渣、其它矿渣和天然火山灰需要额外的能耗。综合以上 能耗数值可知，粉煤灰需要的额外电耗为 20 kWh/t 粉煤灰，矿渣需要的额 外电耗为 38kWh/t 矿渣。天然火山灰的额外电耗假设与粉煤灰相同。这些 数据可用于运算水泥粉磨电耗。混合材烘干热耗的最佳水平是0.75GJ/t(26kgce/t)混合材。一样情形下，只有高炉矿渣和其他矿渣需要烘干。那些 需要烘干的混合材(默认情形是所有矿渣，尽管用户能够在生产信息输入 表中输入该数据)的最佳烘干热耗为 0.75GJ/t (26kgce/t)混合材。-KilnClinker production can

20、 be split into the electricity required to run the machinery, including the fans, the kiln drive, the cooler and the transport of materials to the top of the preheater tower (“kiln preheaters” and “ cooler system” ), and the fuel needed to dry, to calcine and to clinkeri ze the raw materials (“preca

21、lcination” , if applicable, and the “kiln ” ). Best practice for clinker making mechanical requirements is estimated to be 22.5 kWh/t clinker, while fuel use has been reported as low as 2.85 GJ/t (97.3 kgce/t) clinker.熟料生产过程的能耗可分为驱动机械设备(如风机、窑的驱动装置、 冷却机和预热器喂料提升机等)的电耗和烘干物料、煅烧生料的燃料消耗。熟料生产的最佳电耗水平是 22.5

22、kWh/t 熟料，最佳燃料消耗水平可低至 2. 85 GJ/t （97.3kgce/t）熟料。Final grinding水泥粉磨 水泥粉磨的最佳电耗水平取决于水泥的细度或比表面积（ cm2/g）。 199 7 年，有文献指出用筒辊磨将水泥粉磨到 3200 cm2/g 的电耗为 25 kWh/t 水泥，粉磨到4000cm2/g的电耗为30 kWh/t水泥。关于中国的水泥，我们 做如下假设：标号为325的水泥的比表面积小于等于 3200 cm2/g;标号为 425的水泥的比表面积约3500 cm2/g;标号为525的水泥的比表面积约40 00m2/g;标号为625的水泥的比表面积约4200 cm

23、2/g。最新的研究认为筒 辊磨的能耗范畴是 16-19kWh/t 水泥。我们以用筒辊磨将水泥粉磨到比表面 积为3200 cm2/g和4000cm2/g的电耗水平作为相应细度的最佳电耗水平， 并按照线性分布假设通过内插和外插运算出比表面积为3500 cm2/g和4200 cm2/g的最佳电耗水平。我们估算得出比表面积为3200 cm2/g的水泥最佳粉磨电耗为16 kWh/t水泥，比表面积为3500 cm2/g的水泥的最佳粉磨 电耗要比3200 cm2/g的水泥高出8%（ 17.3 kWh/t水泥），4000 cm2/g的 水泥的最佳粉磨电耗比 3200 cm2/g的水泥高20%（ 19.2 kW

24、h/t水泥），42 00 cm2/g的水泥的最佳粉磨电耗比 3200 cm2/g的水泥高24%（ 19.8 kWh/ t 水泥）。我们用这些值又估罢了其他类型水泥的最佳粉磨电耗，估算过程 中考虑了混合材的粉磨电耗。我们假设一般硅酸盐水泥的粉磨能耗与硅酸 盐水泥相当，矿渣水泥的矿渣含量平均为65，粉煤灰水泥的粉煤灰含量平均为 35，火山灰的粉磨能耗与矿渣的粉磨能耗相当（掺加量差不多上 65），并假设含 5额外石灰石的石灰石水泥的粉磨能耗与矿渣粉磨能耗 相当。-Other production energy uses其他生产能耗Some cement facilities have quarries on-site, and those generally use both trucks and conve