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外文翻译---窑炉的节能减排与余热利用

英文文献

Energy saving furnace and waste heat utilization

First, macro-surface

Dealing with the fire kiln, furnace output by the daily life of most products occupy, which is also an important part of modern society. Dealing with fire, it involves combustion, involving insulation, related to emissions, so that people attached furnace industry a better life, an attached greenhouse gases and harmful gas emissions, its important can be seen. Based on this understanding, the Copenhagen meeting, if the furnace industry changes, can bring immediate results.

1, the quality of the pursuit of the furnace of the pursuit of product quality, can bring twice the impact. Just think, give up this purpose, what will bring serious consequences. Take the building ceramics industry, the turn of the century, the development of Foshan ceramics impressive, as Foshan, even people relish. But cool to think, how much consumption of Foshan ceramics fossil raw materials, chemical raw materials and fuel? Large number of ceramic products has still retained in our home and decoration of public facilities? In other words, is not there for 10 years or 20 years of happiness and joy in exchange for future generations or even centuries of tragic years? starting from 2009 the national expansion of construction ceramics industry, race, location far below the level of Foshan. The development of society should be going up, and such a situation, energy conservation and emission reduction in crying today, means that we will face even greater tragedy! Industrialization is a perpetual motion machine, not long before the earth disappear ceramic raw materials and fuel can depleted. Besides, we have begun to face non-ceramic material can be dug, recoverable state. The sake of our posterity, we have to consider seriously some of the problems.

The needs of low-quality low-end success of the furnace equipment and other manufacturing equipment market? Or the other hand, because of backward production facilities, it has cultivated a low-end market? This is a subject not tell Road, unknown, but the result is yes, the building ceramics products, the products of low quality means durability, poor persistence, in the near future (maybe this time is about 10 years), social development, and now the rural market and low-income groups, a significant portion of will be renovated, which in turn is a tremendous waste. China is a big country, but it is also resource poor countries, must be considered in the durable goods production conditions, development of appropriate national policy, or economic prosperity, social prosperity will not last long.

Product quality and production equipment for quality products is the largest energy source. Good equipment must be able to produce a good product, good equipment, but it is also more durable and energy efficient, resulting benefits are double. Grasp the product quality, focus on the quality of equipment, saving energy is the key link. We can do this kind of discourse, low quality of the equipment (usually cheap), I will not speak a certain low-quality products and low-cost, on the device itself, may be faced with three years of minor repairs to five years The overhaul, maintenance costs do not say, may soon be eliminated, while the need to remove obsolete equipment, recycled, pay a considerable cost recovery. China's economic development in the early, low-cost investment to make the first pot of gold enterprise development, and enable enterprises to gradually regulate, grow, is feasible but should be necessary, but with considerable capital scale of today, still make such repeat the story, it had to say our sad! if not well resolved, which will be a moment for the future lay hidden dangers of national disaster.

2, industry standards and other thermal equipment furnace is actually involved in multidisciplinary industry, no rules to follow in a few years. Kiln industry norms, can be

divided into the following areas:

First, practitioners, furnace and other thermal equipment industry is essentially a high threshold for industry, country or the relevant trade associations should be the main furnace design and manufacturing, to be provided for construction workers, limiting their qualification.

Followed by furnace and related enterprises to implement qualification system for personnel, equipment and operation of enterprises and to validate the request.

The third is a thermal furnace and related equipment, the product itself to develop industry standards. Furnace product to solve the temperature problem, that firing system (or pressure systems) or heat treatment. Used for different purposes, different temperature, the kilns are classified, on the furnace design, material selection, selection of auxiliary equipment, combustion and control, manufacturing, installation and commissioning of equipment and other aspects of security in particular is a refractory, burner and control system, furnace control systems were provided. In addition, it must be the performance of the product itself, such as furnace fuel consumption indicators, power consumption targets, emission targets, control the level of development testing, evaluation criterion.

Kilns is that most sources of industrial and domestic products, the furnace industry to progress only in the specification, the furnace industry and progress, and industry to progress, social order and progress! What is more, our emission reduction becomes possible.

3, R & D investment industry furnace is interdisciplinary, involving materials science (steel and refractory materials, etc.), combustion and control studies, thermal engineering, mechatronics, automation and control and many other branches of science. Kiln industry is also an ancient industry, has a long history of ancient China, there kilns, Jun ware, kiln, etc., prestigious, but ultimately are kiln, not energy. Furnace of history, is the history of civilization, with the technology, the furnace has also been rapid development of the industry, gave birth to the modern material civilization. All highly sophisticated materials such as aerospace materials, special materials (such as high temperature materials, high strength materials, corrosion-resistant materials, etc.) and so on, no furnace is not a masterpiece. China's technological strength behind the western countries, one important aspect, that is, behind the furnace industry. Furnace with the aforementioned development of the industry's development in all subjects, or conversely, to the latest developments in technology disciplines applied to the furnace industry, facilitate the development and progress of the furnace industry, and then consolidate the material of modern civilization. In China, the economic principle of priority, the lack of kiln industry standards, resulting in the furnace product quite a mixed bag, and then fired low-end products so popular in the market. This is the first, that as new technologies are the means the cost of Zeng Jia, causing the user does not seek the introduction of new technologies; the other, takes in this area of research and development is backward Yu Fadaguojia's.

Second, the design and manufacture of furnace

First, the production of precision; First, the latest technology. Intelligent furnace and related products, is our pursuit. The latest Combustion Theory and combustion equipment (system), the latest control technology in our products can be applied.

To adapt to continuous production of roller kiln tunnel kiln and take the following measures to ensure the quality of the furnace so as to enhance the energy efficiency of the furnace:

1, optimal design. Different products for different customers, different output curves at different temperatures for specific design to meet the product in the case of firing, as saving space, as adapted for multi-product, multi-system firing. In the design and implementing the following basic techniques:

①thermal equilibrium bifurcation diagram. According to bifurcation diagrams, before

embarking on the design of the furnace to make a basic thermal calculation. Bifurcation picture shows the designer pointed out the basic design direction. For example, the treatment of the kiln, the flue gas treatment, can be seen from the bifurcation diagram comes in many forms. Different furnace, thermal equilibrium bifurcation diagram similar.

②high quality materials, including steel and refractory materials. Furnace steel and refractory materials is the basic principal is directly related to the durability and energy-saving furnace indicators. Furnace with fire, dealing with the high temperature products, working environment. Any carelessness furnace structure, would have serious consequences, so the main selection of the furnace must be cautious.

Steel manufacturers have to use the regular high-quality steel, welded solid, polished, rust decontamination, spray rust (zinc-rich paint the best choice) and the metal finish. After such processing and production of long steel will not rust, durable.

Selected according to temperature requirements refractory thermal conductivity, specific gravity (heat specific volume), have better physical properties of high temperature materials, with special emphasis on the consistency of quality materials to ensure that the furnace used to heat □ high to low heat and kiln regenerator, and the furnace to a long life.

2, in addition to the conventional technology, the company also follows for the roller kiln tunnel kiln and unique technology:

①pressure balance system using waste heat. In diameter, under certain conditions, flow depends on the pipeline pressure. And so the company developed the principle of waste heat recovery systems, waste heat can be done for different purposes without the slightest impact on the normal operation of the furnace.

②impulse control impulse control is actually the closest to micro-combustion system variable control theory. Temperature curve for each rise or insulation is actually variable Δ by numerous micro-component heat input, while the pulse is characterized by the need to control the heat input is a fire, do not completely closed when the burner is to do a small variables, to ensure that the temperature curve of continuous and smooth. In addition, since pulse is varied between zero in the fire and, together with the random pulse system balance, high-temperature gas inside the furnace due to mixing and considerable homogenization. So pulse system for wide-body kiln, need a minimum temperature of the products or firing, there is a distinct advantage.

③furnace control PLC + HMI + SCADA system with high-quality, accurate and constant heat output of the combustion and control system, makes the PLC control in the furnace on the practical application possible. The PLC application, supplemented by detailed data such as burner combustion power, fuel air-fuel ratio, temperature curves characteristics, pipeline pressure drop, so that intelligent control of the entire furnace can be effectively achieved. It is worth mentioning that the use of temperature (or pressure) module, due to the use of the PID loop's proportional, integral, differential technique, and these parameters can be set according to different use of the environment, making their application form with the normal temperature control is more effective. HMI that is touch screen user interface for the furnace operation. The company introduced the furnace operating SCADA system is based on iFax4.0 infinite point spread over the Chinese Internet version developed with its function is very powerful.

④gas emission reduction and the use of hot flue gas take away a large proportion of the total heat that can use this part of the heat up, will bring great economic benefits. The Company will adopt two measures of the gas processing:

A semi-automatic and efficient development of the whole closed drying system, full use of flue gas heat.

B the porous ceramics used for flue gas treatment.

Conclusion The primary direction of energy saving furnace is the quality of the furnace,

the State should introduce appropriate measures to restrict the backward, poor materials used in the furnace product, because of inferior materials, in addition to leading to high repair rate, but also led to high elimination rate, operating costs and depreciation costs considerably. Inspection tour in the UK, have seen a kiln for over 30 years, and I was so sad, so kiln made quality to the view of the hope aroused sympathy from colleagues and users. Based on the quality, energy-efficient furnace is the direction of new technology in the successful application of furnace engineering, because any new technology, will certainly bring great economic benefits. And to energy-efficient furnace, to a large extent, is also reducing emissions.

窑炉的节能减排与余热利用

一、宏观面

窑炉是与火打交道的,经窑炉产出的产品占据着日常生活的绝大部分,因而也是现代化社会的重要组成部分。与火打交道,就涉及到燃烧、涉及到保温、涉及到排放,所以窑炉行业一头连着人们美好的生活,一头连着温室气体与有害气体的排放,其举足轻重可见一斑。基于如此的认识,哥本哈根会议之后,如果在窑炉行业推行变更,即可带来立竿见影的效果。

1、品质化追求对窑炉产品品质化的追求,能带来双倍的收效。试想想,放弃此宗旨,会带来何等严重的后果。就拿建筑陶瓷行业来说,上世纪末本世纪初,佛山陶瓷的发展令人瞩目,为佛山人、甚至国人津津乐道。但冷静来想,佛山的陶瓷消耗了多少化石原料、化工原料与燃料?庞大的陶瓷产品中有多少至今仍保留在我们的家居与公共设施的装饰中?也就是说,是不是存在着10年或20年的幸福与快乐换来未来子孙百年甚至数百年的悲惨?从09年开始的全国建筑陶瓷行业的竞相扩张,定位大大低于佛山的水平。社会的发展应当是往上走的,如此的局面,在呼喊节能减排的今天,意味着我们将面临更大悲哀!工业化是一个永动机,不要多久,地球上的陶瓷原料与燃料就可消失殆尽。何况我们已经开始面临无陶瓷原料可挖、可采的境地了。为了我们的后辈,我们不得不严肃地去考虑一些问题。

是低品质的需求成就了低端窑炉设备与其他制造设备的市场?还是反之,是因为生产设施的落后,才培育了低端产品市场?这是一个说不清道不明的课题,但结果是肯定的,就建筑陶瓷产品而言,低品质意味着产品耐用性、持久性差,不久的将来(也许这个时间就是10年左右),社会发展了,现在的农村市场和低收入群体,相当大一部分将会翻新,这又将是极大的浪费。中国是个人口大国,同时又是资源穷国,在耐用品生产方面必须考虑国情,制定相应国策,否则经济的繁荣,社会的繁荣将不会长久。

产品的品质和生产产品的设备的品质是最大的节能源泉。好的设备一定能生产出好的产品,好的设备同时又是更经久耐用和节能的,由此产生的效益是双倍的。抓产品的品质、抓设备的品质,才是节能减排的纲。我们可以做这样的论述,低质的设备(通常是低价的),先不说生产的产品一定低质与低价的,就设备本身而言,面临的可能是三年的小修、五年的大修,维修成本不说,可能很快被淘汰,而淘汰的设备需要拆除、回炉,付出相当的回收成本。在我国经济发展初期,靠低成本投资赚取企业发展的第一桶金,然后使企业逐步规范、壮大,是可行的而且也应是必要的,但具有相当资本规模的

今天,仍然让如此的故事重复,这不得不说是我们的悲哀!如不很好的解决,这必将会为未来某个时刻民族的灾难埋下隐患。

2、行业规范窑炉及其他热工设备实际上是涉及多学科的行业,多年来几无规范可循。窑炉行业的规范,可以分为以下几方面:

首先是从业人员,窑炉及其他热工设备行业本质上是一个高门槛行业,国家或有关行业协会应当对窑炉的设计与主要制造、施工人员加以规定,限定其资质要求。

其次是窑炉及相关企业要实行资质制度,对人员、设备及企业运作提出要求并进行审定。

第三是对窑炉及相关热工设备产品本身制定行业标准。窑炉产品解决的是温度问题,即烧成制度(或压力制度)或热处理。针对不同使用目的、不同使用温度,对窑炉进行分类,对窑炉的设计、选材、辅助设备选型、燃烧与控制、制造、安装与调试以及设备的安全性等方面特别是对耐火材料、烧嘴及其控制系统、窑炉控制系统等进行规定。除此之外,还必须对窑炉产品本身的性能如燃耗指标、电耗指标、排放指标、操控水平等制定检测、评判标准。

窑炉是绝大部分工业和生活产品的来源,窑炉行业只有在规范中才能进步,窑炉行业进步了,工业才能进步,社会才能进步!更甚者,我们的减排才成为可能。

3、研发投入窑炉是多学科交叉行业,涉及到材料学 (钢结构与耐火材料等)、燃烧与控制学、热工学、机电学、自动化与控制学等多分支。窑炉行业同时又是古老的行业,具有相当长的历史,古时的中国就有龙窑、钧窑、官窑等,享有盛誉,但归根结底都是土窑,不节能。窑炉的历史,就是文明进程的历史,随着科技的发展,窑炉行业也有了飞速的发展,催生出了现代的物质文明。所有高尖端材料如航天航空材料、特种材料(如高温材料、高强度材料、耐腐蚀材料等)等,无不是窑炉的杰作。中国的科技实力落后于西方发达国家,其中重要的一方面,就是窑炉行业的落后。窑炉行业的发展是与前述的各学科的发展息息相关的,或者反过来说,把各学科的最新发展技术应用到窑炉行业,促进了窑炉行业的发展与进步,进而夯实了现代的物质文明。在我国,由于经济优先的原则,窑炉行业规范的缺失,导致窑炉产品鱼龙混杂,进而使低端烧成产品在市场上大行其道。这是其一,也就是说由于新技术都是意味着成本的增加,导致用户不会主动采用新技术;其二,我们在相关领域的研发方面也是落后于发达国家的。

二、窑炉的设计与制造

一是精工的制作;一是最新技术的应用。智能化的窑炉及相关产品,是我们的追求。最新的燃烧理论与燃烧设备(系统),最新的控制技术都在我们的产品中得以应用。

对于适应于连续式生产的辊道窑与隧道窑采取如下措施确保窑炉的品质从而提升窑炉的节能性:

1、优化设计方案。对不同用户的不同产品、不同产量、不同温度曲线作针对性设计,在满足产品烧成的情况下,尽可能节约空间,尽可能适应于多产品、多制度的烧成。在设计中贯彻以下基本技术:

①热平衡分叉图。根据分叉图,在着手窑炉的设计之前作一基本的热工计算。分叉图为设计师的设计指明了基本的设计方向。比如说对窑体的处理,对烟气的处理,从分叉图可以看出孰轻孰重。不同的炉型,热平衡分叉图大同小异。

②采用优质材料,包括钢材与耐火材料。钢材与耐火材料是窑炉的基本主体,直接关系到窑炉的耐用性和节能指标。窑炉是与火,与高温打交道的产品,工作环境恶劣。窑炉结构的稍有不慎,将会带来严重后果,所以窑炉的主体选材必须慎之又慎。

钢结构必须选用正规厂家的优质钢材,焊接牢固、打磨、除锈除污、喷防锈漆(最好选用富锌漆)与金属面漆。经如此处理与制作的钢结构才会长期不生锈,经久耐用。

耐火材料依温度要求选用导热系数、比重(热比容)、高温物理性能均较佳的材料,同时特别注重材料品质的一致性,确保窑炉使用时至高的保温□热性和至低的窑体蓄热,以及窑炉至长的使用寿命。

2、除了上述常规的技术外,本公司还有如下针对辊道窑和隧道窑的独特技术:

①余热利用压力平衡系统。在管径一定的条件下,流量取决于管道压力。依此原理本公司开发出的余热利用系统,可以将余热做不同用途而不致丝毫影响窑炉的正常工作。

②脉冲控制系统脉冲控制实际上是最接近于微变量控制理论的燃烧系统。温度曲线上的每一上升或保温实际上是由无数的微变量Δ热输入组成,而脉冲控制的特点就是需要热输入时是大火,不需要时烧嘴完全关闭,正是做到了一个细小的变量,确保了温度曲线的连续、平滑。除此之外,由于脉冲是在大火与零之间变化,加上脉冲系统的随机均衡性,整个窑炉内部的高温气体因搅拌而相当均化。所以脉冲系统对于宽体窑,或者需要极小温差的制品烧成,有明显的优势。

③窑炉控制PLC+HMI+SCADA系统有了高质量的、热输出恒定准确的燃烧与控制系统,使得PLC在窑炉操控上的实际应用成为可能。而PLC的应用,辅以详实的燃烧数据如烧嘴功率、燃料空燃比、温度曲线特性、管道压降等,使窑炉的全智能控制得以有效地实现。值得一提的是采用温度(或压力)模块,由于运用了PID回路的比例、积分、微分技术,而这些参数又可根据不同使用环境进行设置,使得其应用相对于普通温控表更有效。HMI即触摸屏,为窑炉操作的人机界面。本公司推出的窑炉操作SCADA系统是基于iFax4.0以上中文无限点扩展网络版开发而成,其功能十分强大。

④烟气的减排与利用烟气带走的热占总热的比重相当大,能够把这部分热利用起来,将会带来很大的经济效益。本公司将采取两方面的措施对烟气进行处理:A开发全封闭半成品全自动高效干燥系统,充分利用烟气热能。

B将多孔陶瓷用于烟气的处理。

结语窑炉节能减排的首要方向是窑炉的品质,国家应当出台相应的措施,限制落后的、劣质的材料在窑炉产品上使用,因为劣质的材料除了导致高的维修率,还导致了高淘汰率,运行成本和折旧成本相当大。在英国考察时,曾见有使用超过30年的窑炉,对我是相当大的震撼,所以提出了窑炉品质论的观点,希望能引起广大同仁和用户的共鸣。在品质的基础上,窑炉的节能方向在于新技术在窑炉工程上的成功应用,因为任何新的技术,一定能带来巨大的经济效益。而能够节能的窑炉,在相当大程度上又是减排的。

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