0311-YQP36預(yù)加水盤式成球機設(shè)計【全套13張CAD圖】
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課題名稱：YQP36預(yù)加水盤式成球機設(shè)計
一、 課題來源、課題研究的主要內(nèi)容及國內(nèi)外現(xiàn)狀綜述
本課題來源于江蘇海建集團股份有限公司。課題研究的主要內(nèi)容是設(shè)計盤徑為3.6m、產(chǎn)量為25t/h的預(yù)加水成球盤。
目前我國水泥企業(yè)，正向著大型化迅速發(fā)展，以海螺集團為首的一批年產(chǎn)1000萬噸以上的大型水泥集團發(fā)展勢頭迅猛，海螺在2002年形成年產(chǎn)4000萬噸的生產(chǎn)能力，躋身于世界10強之列?；A(chǔ)條件較好的立窯水泥企業(yè)，通過推廣應(yīng)用20項適用技術(shù)，正在向現(xiàn)代立窯企業(yè)和經(jīng)濟規(guī)模化發(fā)展，以塔牌集團為首一批年產(chǎn)100萬噸以上大型立窯水泥企業(yè)，已加入發(fā)展經(jīng)濟規(guī)模新型干法之列。
我國水泥2002年年產(chǎn)總量雖然已經(jīng)達到7億多噸，但立窯水泥仍占70%，在現(xiàn)階段，現(xiàn)代立窯還是一種比較符合國情的適用技術(shù)。立窯生產(chǎn)工藝由于它的單機生產(chǎn)能力小，勞動生產(chǎn)率低和難以實現(xiàn)自動化生產(chǎn)等缺點，難以與大型新型干法企業(yè)競爭，逐步被新型干法或更新的技術(shù)所取代，是我國水泥工業(yè)發(fā)展的歷史必然。但由于國民經(jīng)濟的持續(xù)高速發(fā)展的拉動，水泥的市場需求仍處在上升期，這就給立窯水泥的發(fā)展提供了空間，這也是為什么在新型干法快速發(fā)展和淘汰了近1億噸立窯生產(chǎn)能力的情況下，立窯水泥的增量仍然大于旋窯水泥增量的原因所在?？梢灶A(yù)言，今后相當(dāng)長的歷史時期，我國水泥工業(yè)還少不了立窯水泥的支撐。因此有生存發(fā)展條件的立窯水泥企業(yè)，要不失時機的逐步與新型干法接軌和發(fā)展新型干法生產(chǎn)線，這是立窯水泥企業(yè)實現(xiàn)可持續(xù)發(fā)展的歷史選擇。
生料制備、水泥粉磨系統(tǒng)等與新型干法技術(shù)的接軌，為立窯水泥企業(yè)的產(chǎn)品質(zhì)量提供了生料質(zhì)量的保證，但窯的煅燒水平最終決定熟料質(zhì)量的優(yōu)劣。通過我國廣大立窯水泥工作者長期不斷地技術(shù)創(chuàng)新，在立窯煅燒技術(shù)上，取得了前所未有的技術(shù)進步和發(fā)展。由于這些新技術(shù)的推廣應(yīng)用，使立窯生產(chǎn)工藝，至今還能作為我國水泥生產(chǎn)工藝中的一種經(jīng)濟實用的技術(shù)方式，與新型干法生產(chǎn)技術(shù)共存。
當(dāng)前立窯煅燒系統(tǒng)，應(yīng)該進一步重點抓好兩項技術(shù)的推廣和粉塵治理。其中預(yù)加水小料球快速煅燒技術(shù)，小料球快速燒成技術(shù)是立窯煅燒的一項重要技術(shù)進步，目前應(yīng)用十分成功的企業(yè)并不多，主要原因是前幾年預(yù)加水成球系統(tǒng)的控制技術(shù)和設(shè)備還不太過關(guān)，小料球的操作控制要點還沒完全掌握，目前預(yù)加水成球技術(shù)已經(jīng)發(fā)展到第六代產(chǎn)品，設(shè)備及控制系統(tǒng)基本過關(guān)。小料球快速煅燒技術(shù)的核心是減小料球平均粒經(jīng)和大小球的差異，也就是將成球的粒度由原來的8～12mm，降低為3～7mm。由于粒球平均直徑大大減小，對加快煅燒速度、提高窯的產(chǎn)量和降低fCaO含量都產(chǎn)生了積極的影響，應(yīng)用成功的企業(yè)都取得明顯效果。
二、本課題擬解決的問題
1．盤底平面和側(cè)平面有出現(xiàn)變形，增加主電機運轉(zhuǎn)負(fù)荷，影響成球質(zhì)量；
2．支架剛度和強度不夠，出現(xiàn)變形；
3．采用行星減速機出現(xiàn)傳動扭矩不足及漏油現(xiàn)象；
4．采用圓柱齒輪減速機出現(xiàn)的漏油以至缺油、磨損現(xiàn)象；
5．盤體轉(zhuǎn)動扭矩大以至減速機輸入軸端鍵和鍵槽的變形與孔軸的磨損現(xiàn)象；
6．采用的傘齒輪副傳動不穩(wěn)定與斷齒現(xiàn)象；
7．固定式無動力邊刮刀磨損及所成球質(zhì)量差和無法保證生產(chǎn)連續(xù)性的現(xiàn)象；
8．動力軸承出現(xiàn)軸承燒壞、鍵槽損壞甚至電機燒壞和小立軸失效的現(xiàn)象；
9．盤式6爪電動刮刀的動力消耗大，成球質(zhì)量低，清盤阻力大、周期長，結(jié)構(gòu)復(fù)雜、不易維修等問題；
10．圓柱形刮刀桿的五爪無動力刮刀中，存在刀桿不易夾緊，徹底清盤一次的周期長，清料阻力大，成球盤動力消耗高等缺陷。
三、解決方案及預(yù)期效果
采用可調(diào)式盤體且在盤底焊接工字鋼以增加盤底的剛度和強度，在盤邊焊接圓鋼以加強盤的徑向剛度。采用無動力邊刮刀和圓鋼焊接成支架以減少刮刀支架所要承受的彎矩。合理布局刮刀的位置以實現(xiàn)成球高質(zhì)量的目的，設(shè)計盤傾角在48°—52°的范圍內(nèi)，盤高在550mm—600mm的范圍內(nèi)。
在傳動系統(tǒng)方面，將采用電機à皮帶àZQ減速機à直齒輪副à成球盤的傳動結(jié)構(gòu)。并且設(shè)計將高速軸端和低速軸端同布置在上側(cè)，以減少軸對密封圈的磨損和解決漏油問題。同時采用圓柱齒輪連接也避免了因傘齒輪的剛性不足而斷齒影響生產(chǎn)連續(xù)性。ZQ減速機高速軸端采用平鍵雙鍵聯(lián)接，使孔軸過盈配合，保證扭矩的正常傳遞而不失效。大小齒輪設(shè)計防塵罩以減輕齒輪嚙合的磨損。主軸采用角接觸球軸承或圓錐滾子軸承以承受主軸軸向力。電機固定在固定底架的側(cè)面，以實現(xiàn)安裝方便的需要。調(diào)整盤轉(zhuǎn)速到11.5r/min，保證成球質(zhì)量。
刮刀系統(tǒng)中，將采用無動力底刮刀結(jié)構(gòu)，以起到節(jié)能、經(jīng)濟的需要。無動力底刮刀采用五邊形刮刀盤，另外在刮刀桿上設(shè)計成方形刀桿和設(shè)計鎖緊結(jié)構(gòu)以解決其軸向的鎖緊問題，也有設(shè)計成十爪方刀桿無動力刮刀以減少動力磨損。在刮刀盤連接的軸的上端安裝一飛輪，以實現(xiàn)盤體轉(zhuǎn)動的調(diào)速作用。設(shè)計刀頭距離盤底保持在10—15mm的距離范圍，以減少刮刀運行中的阻力降低主機電流，保證產(chǎn)量要求；在刀頭部焊接小型耐磨合金塊來減少刀頭磨損。將采用無動力固定式邊刮刀，在形狀和結(jié)構(gòu)上做相對調(diào)整改進，如采用可換式刀頭，以解決起刀桿變形而導(dǎo)致的清料質(zhì)量差的問題。
為了保證成球盤在運轉(zhuǎn)過程中的穩(wěn)定性，設(shè)計中將大量采用剛度和強度好的型鋼焊接成底架，增加它的承壓面。在調(diào)角器方面，采用蝸輪蝸桿傳動和螺紋的軸向傳動的原理制成，滿足盤傾角的鎖定要求，另外根據(jù)客戶使用要求也可采用液壓裝置實現(xiàn)調(diào)試。
此次設(shè)計本著高產(chǎn)量、高質(zhì)量成球，穩(wěn)定運轉(zhuǎn)的原則，實現(xiàn)預(yù)加水成球盤要求的節(jié)能性、經(jīng)濟性、環(huán)保性、可擴展性。
四、課題進度安排
3月6日～3月17日．畢業(yè)實習(xí)階段。
畢業(yè)實習(xí)，查閱資料，到多個公司實踐，撰寫實習(xí)報告。
3月18日～3月31日．開題階段。
提出總體設(shè)計方案及草圖，填寫開題報告。
4月1日～5月10日． 設(shè)計初稿階段。
完成總體設(shè)計圖、部件圖、零件圖。
5月11日～6月4日． 中期工作階段。
完善設(shè)計圖紙，編寫畢業(yè)設(shè)計說明書，中期檢查。
6月5日～6月7日．畢業(yè)設(shè)計預(yù)答辯。
6月8日～6月13日．畢業(yè)設(shè)計整改。
圖紙修改、設(shè)計說明書修改、定稿，材料復(fù)查。
6月14日～6月16日．畢業(yè)答辯。
6月17日～6月18日．材料整理裝袋。
五、指導(dǎo)教師意見
年 月 日
六、專業(yè)系意見
年 月 日
七、學(xué)院意見
年 月 日
2
Feasibility study requirements for a new cement plant
R.Hogg, D Frame and M.E. Asim, WS Atkins Consultants, UK, discuss the theory and practice of undertaking large cement plant projects.
FOR SPANISH AND FRENCH VERSIONS PLEASE REFER TO THE SPECIAL TRANSLATED SECTION AT THE BACK OF THE ISSUE
Introduction
The decision to start the construction of an entirely new cement plant facility, or a major capacity extension at an existing cement works, should always be based on a detailed techno-economic feasibility study. Such a study will indicate to the promoter the viability of the business in terms of the best technical solution, the overall capital and operating casts, the magnitude of the operation in terms of production and workforce needed, and the return on his investment over a period of time.
A typical feasibility study deals with the following issues:
Marketing study.
Raw materials proving.
Site studies.
Conceptual engineering and process design.
Analysis of alternatives.
Project cost including infrastructure.
Project schedule.
Investment analysis, risk assessment, development of financial structures.
Project finance.
Discussion with financing institutions.
Whilst any feasibility study must include technical aspects, it is important to realize the full implications of marketing research and accurate financial projections.
Pro-feasibility study
In order to minimize front end expenditure and to quickly obtain a firm indication of the likely project viability, a pre-feasibility study is performed.
The pre-feasibility study is carried out at low cost, but in sufficient detail to show whether a full feasibility study is justified. The pre-feasibility study will examine the market place, the raw materials, capital and operating costs, and develop a business plan to show the likely returns on the investment, and identify the risks and scale of operation involved.
Typically this exercise will take four to six weeks to complete, commencing with a site visit. However, the study is largely performed by desk research and reference to the in-house date base. The site visit is used to determine the suitability of raw materials for cement manufacture, local building and civil engineering costs, cost of land and peculiarities of the particular site location, and local cost of consumables required in the operation of the plant. The desk research concentrates upon current plant and machinery costs, financial and marketing considerations and preliminary plant sizing and determination of the process route.
In the event of the pre-feasibility study showing a clear indication that it is worthwhile to proceed with the project, then a full feasibility study can be initiated.
Full feasibility study
Market research
The objective of the market study is to establish the demand for the various types of cement in the context of the region or market area of the proposed plant. The study seeks to establish the current and forecast cement usage over a 5-7 year period. The forecast is then used together with the indicated selling prices to generate the likely revenue stream for the proposed operation.
The consultant must have considerable experience in the global cement industry and be able to approach a feasibility study with an excellent knowledge of prevailing market conditions and likely trends. Each individual company and market does, however, present a unique set of circumstances which must be fully understood. The normal approach adopted is first to study the company and identify its strengths and weaknesses, strategic direction and motivation. This is essential in providing an immediate picture of the company’s likely success in achieving its aims.
The second stage of the marketing survey, desk research, puts the initial discussions into context by examining a wide range of published data relevant to the industry.
Sources of published data are collated and compared by a team of researchers and consultants in an operation to substantiate known trends and uncover new information. It is not sufficient to rely on information several months old, and without an international perspective, trends in cement production and demand are frequently misleading.
Collecting published data is an on-going process, but having established a background to the study, information should, where possible, be verified using independent sources with firsthand accounts of the industry and its outlook. Companies, government organisations and other industry associations are often willing to provide their own assessment lf markets, but care needs to be taken not to compromise any party prepared to give its view.
Armed with a comprehensive selection of published data and industry opinion, the job of the consultant at this stage is to accurately define not only the market size for a particular product, but the likely change in that market. Such changes are often predicted by historic relationships between, for instance GDP and overall construction activity; economic growth and housing starts of cement consumption and population size. Figure 1 illustrates this point. Without taking into account subjective opinion and recognizing changing user requirements for different cement types, such forecasts can be flawed. Analysis of such factors is particularly important in lesser developed countries where impressive growth rates can change the balance of construction activity over remarkably short periods of time.
Other economic information likely to have a bearing on the market are government tariffs, import duties and sector subsidies. Even in free market areas, many aspects of economies are regarded as being of strategic importance and governments frequently strive to preserve national interests wherever possible by fixing prices of imposing import tariffs. Should import tariffs be relaxed of prices allowed to move in line with supply and demand, there will be an appreciable change in the market conditions. National companies, for instance, might suddenly find themselves uncompetitive. With cheaper imports, the balance between cement grinding and clinker production requirements could change quite dramatically. It would be up t the government to accommodate these changes, but one of the principle tasks of the consultant is to anticipate them.
This last point highlights what is perhaps the single most important yet difficult to determine aspect of a market study: competitor reaction. Knowing of others investment plans, government licensing, likely dates of completion, principle contractors involved and distribution partners is difficult and time consuming, but it is not enough. Competitors are not just nationals of those who have historically sold their product through the same predictable channels of distribution. There are an increasing number of companies who would like to reduce dependence on suppliers by vertically integrating their operations. This could entail building their own plant or developing their own deep water terminal to import cement directly. Others might decide to diversify into selling, for example, ready missed concrete. Some large users might be on verge of entering into long term agreements with one company or looking to buy form further afield. The combinations are numerous but it is up to the company investing in expensive plant and machinery to understand its customers and convince both itself and the investors that it really does have the best view of the market.
Raw materials proving
The volume and quality of the raw material deposits have to be established with accuracy. A wide ranging search for raw materials may start with desk research and consultation with National Geological Survey data and available geological mapping. The search will include examination of aerial photography records and satellite imagery e.g. Landsat or SPOT.
The desk research is followed buy site visits to the proposed location by geologists who take the study a step forward by making on-site examinations of previously identified geological horizons and outcrops. The first samples are taken by channeling from promising outcrops, road cuttings, recent excavations or from purpose excavated test pits. Field testing of the samples is required to provide an initial indication of the calcium carbonate, silica, alumina and iron content of the deposit. The testing is simple, rapid and economical and the geologist can adjust the field investigations and maximize the recovery of useful information.
The most promising samples are chemically analysed in testing laboratories and when sufficient data has been obtained in terms of chemical quality, and the probable volume established, a decision to mount a full drilling campaign can be made.
The primary raw material or limestone, is core drilled and careful records of the geological progression is made as the cores are recovered, recorded and laid sequentially in the core boxes,(Figure 2). Individual and composite samples are taken from the cores and sent to laboratories experienced in the testing of cement raw materials. In order to minimize drilling costs is essential that the initial results of the first borehole are analysed rapidly and the results known in order to make further decisions on location, angle and direction of subsequent boreholes.
The information obtained from the chemical analyses and the geological record derived from the cores in then used to establish the geological structure and the volume of the deposit. The optimum quarry developments are then developed.
The secondary raw materials, clays or shales, may be proven by means of auger drilling of by test pit excavation using mobile hydraulic excavators or in some cases by hand excavation. These materials are similarly recorded and chemically analysed as for the limestones.
Using the chemical analysis of the raw material, computerized raw mix designs can be carried out. The in-house program used has several facilities which can be called upon. Firstly, all the necessary standard equations which must be satisfied for lime saturation, silica ratio, alumina ratio, hydraulic modulus, etc., are built into the program. Secondly, the mix design can be refined by adjusting the compound composition and observing the effect upon the standard ratios. Finally, cost factors can be added to the raw materials to obtain the optimum raw mix which minimizes the most expensive raw materials, but satisfies the above criteria.
Process design
The optimum process route for a specific plant is dependent upon a number of factors including the physical and chemical nature of the raw material deposits. The selection of plant and machinery is made based on the following factors”
Disposition of the raw material deposits.
Moisture content and other physical properties of the raw materials.
Level of undesirable chemical elements.
Mineralogy (particularly the content and size of silica).
Abrasiveness, grindability and the burnability of the raw materials.
Fuel types and relative costs.
Environmental protection requirements.
Electrical power availability, cost and energy efficiency requirements.
Site topography and congstraints.
Market constraints.
Labour and maintenance constraints.
The disposition of the raw materials in terms of dip and strike and physical location dictate how the primary and secondary raw material quarries are opened up, how they are to be worked and how the access roads are to be developed. The geological method of deposition and hardness of the raw materials will also determine how the quarry is to be planned and the methods of extraction determined.
The moisture content of the raw materials and the change in their characteristics as the moisture content alters has an important effect upon the choice of the primary crusher and storage systems. The moisture content has even greater implications when considering the raw milling system to be proposed in conjunction with the optimum temperature of preheater exit gas. A balance has to be struck between the requirements of the kiln system, the number of cyclone stages that can be used, and the heat requirements of the raw mill for raw materials drying.
The level of undesirable chemical elements in the raw materials, such as potassium, sodium, magnesia, chlorides and sulfur requires careful consideration in the selection of the type of kiln system. The varying levels of impurity elements in conjunction with the sulfur in the raw material and possible additional sulfur intake from the kiln fuel, lead to the necessary decisions to be made relating to the acceptance and sizing of a bypass system.
The mineralogy can vary greatly among raw materials in different countries. The method of deposition and the occurrence of the chemical elements in each of the raw materials can have a marked effect on the characteristics of combination in the kiln burning process. Notably this leads to variations in kiln fuel conditions. Predictions upon how the raw-materials will behave when combined in the necessary proportions to obtain a commercial cement, are based upon laboratory burning and grinding tests conducted as part of the feasibility study.
Energy and fuel usage are two key matters high on the agenda of all potential and existing cement plant operators. The cement industry has always been very conscious of making the maximum use of heat energy, and to this end heat transfer from the kiln gases to the raw materials, of from the hot clinker to the combustion air, has always been utilized.
Today more than ever the efficient use of energy and fuel is sought affair and a range of plant and equipments available for consideration. Technical economy of scale is also an important factor and where the market justify large capacity plant, correspond with reductions in the cost of products are achieved.
Energy consumption is be reduced through the use of roll-milling systems for raw meal in plant of tube mills, high efficiency separators in both the raw milling and cement milling departments, low pressure drop cyclones in the preheater of the burning process, and by the preheater of high pressure grinding rolls, and recent introduction of the horizontal roller mill, the so-called Horomill. The selection of the optimum planning processes ensures that the KWh/h electrical power consumption minimised.
Fuel consumption is reduced the introduction of efficient cyclones construction with heat resistant tubes and an increase in the number of stages of preheater to mount maximum use of the hot gases leaving from the kiln. Fuel consumption is also siderable affected by the designation ancillary plant such as the kiln separators, gas ducting, kiln burner, flow control valves and instrumentation.
Another recent development is the transfer of all the hot exhausted gases form the clinker cooler back onto the raw mill, thus saving on the heat required for drying the raw material. This arrangement also has the acute advantage of reducing the capital of the plant by the elimination of a cipitator or other clinker cooler collection system and its associating equipment.
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