煤矸石、尾矿代粘土匹配低品位石灰石煅烧水泥熟料试验研究
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摘要
我国水泥产量位居世界首位,生产水泥需大量粘土和石灰石,而开采这些资源会破坏植被,影响环境。大量弃置的煤矸石、尾矿则占用土地,污染环境,甚至诱发地质灾害。本文以拓宽水泥原料为研究背景,依托国家“十一五”科技支撑计划重点项目：“煤矸石资源化关键技术研究”,对煤矸石、尾矿、低品位石灰石煅烧水泥熟料进行试验研究和理论分析。
本文根据新型干法回转窑煅烧水泥熟料理论,主要进行了实验室试验研究、理论分析和工业试验等方面的工作。实验室试验研究主要包括：(1)煤矸石、石灰石的粉磨试验研究,(2)煤矸石、石灰石、尾矿理化特性及热解分析,(3)熟料煅烧的影响因素试验研究,(4)水泥熟料水化性能分析。理论分析主要包括：(1)粉体颗粒群粒径分布、粉体紧密堆积模型研究以及粒度分维预测,(2)煤矸石、尾矿和石灰石的热解动力学机理研究,(3)水泥熟料强度预测模型研究,(4)煤矸石、尾矿配低品位石灰石煅烧水泥熟料形成机理分析。最后,在新型干法回转窑上进行部分工业试验以及效益分析。
煤矸石、石灰石的粉磨试验发现煤矸石易磨性不如砂岩,配低品位石灰石的水泥生料在粉磨初期易磨性比配高品位石灰石生料稍差,到后期则相接近。粉磨数据进行粒径分布、粉体紧密堆积模型研究验证了试验结论。
对煤矸石、尾矿、石灰石等进行理化特性分析,结果表明煤矸石和尾矿均属粘土类物质,其重金属含量均优于三级土壤标准和农用粉煤灰中污染物控制标准；研究他们的热解动力学发现,随着热解反应的进行,煤矸石、石灰石、尾矿所需的活化能增加,高品位石灰石热解所需活化能要高于低品位石灰石。
熟料煅烧的影响因素试验研究结果表明：温度是决定熟料质量主要因素之一,试验中烧成温度不高于实际水泥生产温度；煤矸石含有一定热值,能促进水泥熟料的烧成；尾矿具有一定地质潜能,能加速煅烧进程；低品位石灰石的化学组成和晶格结构等与高品位石灰石的差异,能降低物料的分解温度,其与尾矿、煤矸石等配制水泥生料,容易进行固相反应。
水泥熟料进行水化性能分析结果可知：随着水化进程的进行和水化龄期的延长,各种水化产物增加,最终成为渐进致密硬化的浆体结构。对熟料进行基于神经网络的熟料性能预测模型研究,建立了误差反向传播(Error Back Propagation, BP)改进模型和径向基函数(Radial-Basis Function, RBF)网络模型,利用煤矸石、尾矿和不同品位石灰石等作为原料配制水泥生料,采用在两个煅烧温度下的熟料所得的主要9个参数为预测模型输入数据,净浆28d强度作为期望输出数据,得出样本输出数据。结果表明,用神经网络的三种水泥熟料预测强度模型训练后的网络是可行的,而且RBF网络模型优于BP改进模型。
对煤矸石、尾矿配低品位石灰石煅烧水泥熟料形成机理进行了研究。主要分析煤矸石、尾矿热活化过程的潜能来源,探讨煤矸石、尾矿、低品位石灰石具有热激发作用。提出了煤矸石、尾矿、低品位石灰石配料的熟料形成动力学理论模型,通过分析物料的CaO转化率和反应表观活化能等参数,表明煤矸石、尾矿、低品位石灰石在煅烧水泥熟料中具有节能作用。
最后,在2500t/d新型干法回转窑水泥生产线上进行了煤矸石、低品位石灰石等煅烧水泥熟料和在5000t/d新型干法回转窑水泥生产线上进行煤矸石代粘土煅烧水泥熟料的工业试验研究,试验结果表明：两生产线可分别年增水泥56381t和280503t,熟料标煤耗每年分别降低3601t和8132t,节约电量分别为1488245kw.h和11351274kw.h,综合利用煤矸石可达29万t。
本文研究工作为煤矸石、尾矿、低品位石灰石煅烧水泥熟料提供了技术和理论参考。
China is the largest cement producers in the word. It needs a lot of clay and limestone to manufacture cement. However, the environment has been influenced because clay and limestone have been exploited. A large number of tailings and coal gangue had been accumulated in the field, which not only took up our land, but also threatened our ecological environment. Facing to discover some new raw materials for cement production, and sponsored by the National Key Technologies R&D Program of China in11th-five-year ("key technology research on resource utilization for coal gangue"), this paper has carried out detailed experimental research and theory analysis on utilization of coal gangue, tailings as clay and mixed with low-grade limestone.
Experimental research, theory analysis and industrial test are carried out according to the theory of cement clinker calcinations in new dry-process rotary kiln. The experimental research includes:(1) grinding experiment to coal gangue and limestone;(2) physical&chemical characters and thermal decomposition research for coal gangue, limestone and tailings;(3) experimental research of influential factors for cement clinker calcinations;(4) the hydration properties analysis to cement clinker. Theory analysis includes:(1) the model of closed packing and predicting fractal dimension for the distribution of particle sizes;(2) kinetics of thermal decomposition for coal gangue, limestone and tailings;(3) strength prediction models for cement clinker;(4) the formation mechanism on utilization of coal gangue and tailings as clay mixed with low-grade limestone for cement clinker calcinations. At last, some industrial test and efficiency analysis are carried out in the new dry-process rotary kiln on2500tons per day (t/d) and5OOOt/d.
The grinding experiment found that the grindability of coal gangue is less than sandstone. The raw meal which is mixed with low-grade limestone has a lower grindability compared to that mixed with high-grade limestone in the initial stage, but has a similar grindability in the last stage. The theory analysis on the modeling of closed packing and predicting fractal dimension to particle sizes also verified the experimental conclusion.
The analysis results of physical&chemical characters for coal gangue, limestone and tailings show that coal gangue and tailings are belong to the clay. The heavy metal components of coal gangue is prior to the third class standard of soil and the standard of pollution control on fly ash for agricultural use. The result of their thermal decompensate kinetics found that their activate energy are increased during their thermal decomposition, and activate energy of high-grade limestone is higher than that of low-grade limestone.
Experimental research of influential factors for cement clinker calcinations showed that temperature is one of the main factors to the quality of clinker. The temperature of clinker sintering is below the temperature of actual production. Coal gangue contains certain calorie capacity which can improve clinker sintering. Tailings contain certain geological potentiality, and it can accelerate burning process. The chemical composition and lattice structure of low-grade limestone are different from that of high-grade limestone. The low-grade limestone can decrease the raw material's decomposition temperature. The material mixed with tailings, coal gangue and low-grade limestone is easy to happen solid state reaction.
The result of hydration properties analysis found that hydration products increased with the time past, and it became cement paste structure finally. The predicted model of improved Error Back Propagation (BP) and Radial-Basis Function (RBF) were set up based on neural networks for cement clinker.9parameters as input datas for predicted model. The expected output datas came from cement paste for28days strength, and the datas of sample were obtained at last. The result showed that it is feasible for three prediction models on cement strength, and the network model of RBF is better to improved model of BP.
The formation mechanism on utilization of coal gangue, tailings as clay and mixed with low-grade limestone was discussed. Potentials of coal gangue and tailings during their thermal-activation were analyzed. The functions of heat excitation were founded in coal gangue, tailings and low-grade limestone. The kinetic model was put forward to them. The kinetic parameters such as the conversion rate for calcium oxide and apparent activation energy. Experimental results showed that they can reduce energy consumption during cement clinker calcinations.
Industrial tests were carried out in the new dry-process rotary kiln of2500t/d and5OOOt/d. The results showed that the two production lines can increase cement output56381tons (t) and280503t in every year. They can save3601t and8132t of the clinker standard coal consumption. The two powers can save1488245kw.h and11351274kw.h. Coal gangue can be used up to290OOOt in each year.
The research in this paper provides a technical and theoretical basis for coal gangue, tailings, and low-grade limestone for cement clinker calcinations.
本文根据新型干法回转窑煅烧水泥熟料理论,主要进行了实验室试验研究、理论分析和工业试验等方面的工作。实验室试验研究主要包括：(1)煤矸石、石灰石的粉磨试验研究,(2)煤矸石、石灰石、尾矿理化特性及热解分析,(3)熟料煅烧的影响因素试验研究,(4)水泥熟料水化性能分析。理论分析主要包括：(1)粉体颗粒群粒径分布、粉体紧密堆积模型研究以及粒度分维预测,(2)煤矸石、尾矿和石灰石的热解动力学机理研究,(3)水泥熟料强度预测模型研究,(4)煤矸石、尾矿配低品位石灰石煅烧水泥熟料形成机理分析。最后,在新型干法回转窑上进行部分工业试验以及效益分析。
煤矸石、石灰石的粉磨试验发现煤矸石易磨性不如砂岩,配低品位石灰石的水泥生料在粉磨初期易磨性比配高品位石灰石生料稍差,到后期则相接近。粉磨数据进行粒径分布、粉体紧密堆积模型研究验证了试验结论。
对煤矸石、尾矿、石灰石等进行理化特性分析,结果表明煤矸石和尾矿均属粘土类物质,其重金属含量均优于三级土壤标准和农用粉煤灰中污染物控制标准；研究他们的热解动力学发现,随着热解反应的进行,煤矸石、石灰石、尾矿所需的活化能增加,高品位石灰石热解所需活化能要高于低品位石灰石。
熟料煅烧的影响因素试验研究结果表明：温度是决定熟料质量主要因素之一,试验中烧成温度不高于实际水泥生产温度；煤矸石含有一定热值,能促进水泥熟料的烧成；尾矿具有一定地质潜能,能加速煅烧进程；低品位石灰石的化学组成和晶格结构等与高品位石灰石的差异,能降低物料的分解温度,其与尾矿、煤矸石等配制水泥生料,容易进行固相反应。
水泥熟料进行水化性能分析结果可知：随着水化进程的进行和水化龄期的延长,各种水化产物增加,最终成为渐进致密硬化的浆体结构。对熟料进行基于神经网络的熟料性能预测模型研究,建立了误差反向传播(Error Back Propagation, BP)改进模型和径向基函数(Radial-Basis Function, RBF)网络模型,利用煤矸石、尾矿和不同品位石灰石等作为原料配制水泥生料,采用在两个煅烧温度下的熟料所得的主要9个参数为预测模型输入数据,净浆28d强度作为期望输出数据,得出样本输出数据。结果表明,用神经网络的三种水泥熟料预测强度模型训练后的网络是可行的,而且RBF网络模型优于BP改进模型。
对煤矸石、尾矿配低品位石灰石煅烧水泥熟料形成机理进行了研究。主要分析煤矸石、尾矿热活化过程的潜能来源,探讨煤矸石、尾矿、低品位石灰石具有热激发作用。提出了煤矸石、尾矿、低品位石灰石配料的熟料形成动力学理论模型,通过分析物料的CaO转化率和反应表观活化能等参数,表明煤矸石、尾矿、低品位石灰石在煅烧水泥熟料中具有节能作用。
最后,在2500t/d新型干法回转窑水泥生产线上进行了煤矸石、低品位石灰石等煅烧水泥熟料和在5000t/d新型干法回转窑水泥生产线上进行煤矸石代粘土煅烧水泥熟料的工业试验研究,试验结果表明：两生产线可分别年增水泥56381t和280503t,熟料标煤耗每年分别降低3601t和8132t,节约电量分别为1488245kw.h和11351274kw.h,综合利用煤矸石可达29万t。
本文研究工作为煤矸石、尾矿、低品位石灰石煅烧水泥熟料提供了技术和理论参考。
China is the largest cement producers in the word. It needs a lot of clay and limestone to manufacture cement. However, the environment has been influenced because clay and limestone have been exploited. A large number of tailings and coal gangue had been accumulated in the field, which not only took up our land, but also threatened our ecological environment. Facing to discover some new raw materials for cement production, and sponsored by the National Key Technologies R&D Program of China in11th-five-year ("key technology research on resource utilization for coal gangue"), this paper has carried out detailed experimental research and theory analysis on utilization of coal gangue, tailings as clay and mixed with low-grade limestone.
Experimental research, theory analysis and industrial test are carried out according to the theory of cement clinker calcinations in new dry-process rotary kiln. The experimental research includes:(1) grinding experiment to coal gangue and limestone;(2) physical&chemical characters and thermal decomposition research for coal gangue, limestone and tailings;(3) experimental research of influential factors for cement clinker calcinations;(4) the hydration properties analysis to cement clinker. Theory analysis includes:(1) the model of closed packing and predicting fractal dimension for the distribution of particle sizes;(2) kinetics of thermal decomposition for coal gangue, limestone and tailings;(3) strength prediction models for cement clinker;(4) the formation mechanism on utilization of coal gangue and tailings as clay mixed with low-grade limestone for cement clinker calcinations. At last, some industrial test and efficiency analysis are carried out in the new dry-process rotary kiln on2500tons per day (t/d) and5OOOt/d.
The grinding experiment found that the grindability of coal gangue is less than sandstone. The raw meal which is mixed with low-grade limestone has a lower grindability compared to that mixed with high-grade limestone in the initial stage, but has a similar grindability in the last stage. The theory analysis on the modeling of closed packing and predicting fractal dimension to particle sizes also verified the experimental conclusion.
The analysis results of physical&chemical characters for coal gangue, limestone and tailings show that coal gangue and tailings are belong to the clay. The heavy metal components of coal gangue is prior to the third class standard of soil and the standard of pollution control on fly ash for agricultural use. The result of their thermal decompensate kinetics found that their activate energy are increased during their thermal decomposition, and activate energy of high-grade limestone is higher than that of low-grade limestone.
Experimental research of influential factors for cement clinker calcinations showed that temperature is one of the main factors to the quality of clinker. The temperature of clinker sintering is below the temperature of actual production. Coal gangue contains certain calorie capacity which can improve clinker sintering. Tailings contain certain geological potentiality, and it can accelerate burning process. The chemical composition and lattice structure of low-grade limestone are different from that of high-grade limestone. The low-grade limestone can decrease the raw material's decomposition temperature. The material mixed with tailings, coal gangue and low-grade limestone is easy to happen solid state reaction.
The result of hydration properties analysis found that hydration products increased with the time past, and it became cement paste structure finally. The predicted model of improved Error Back Propagation (BP) and Radial-Basis Function (RBF) were set up based on neural networks for cement clinker.9parameters as input datas for predicted model. The expected output datas came from cement paste for28days strength, and the datas of sample were obtained at last. The result showed that it is feasible for three prediction models on cement strength, and the network model of RBF is better to improved model of BP.
The formation mechanism on utilization of coal gangue, tailings as clay and mixed with low-grade limestone was discussed. Potentials of coal gangue and tailings during their thermal-activation were analyzed. The functions of heat excitation were founded in coal gangue, tailings and low-grade limestone. The kinetic model was put forward to them. The kinetic parameters such as the conversion rate for calcium oxide and apparent activation energy. Experimental results showed that they can reduce energy consumption during cement clinker calcinations.
Industrial tests were carried out in the new dry-process rotary kiln of2500t/d and5OOOt/d. The results showed that the two production lines can increase cement output56381tons (t) and280503t in every year. They can save3601t and8132t of the clinker standard coal consumption. The two powers can save1488245kw.h and11351274kw.h. Coal gangue can be used up to290OOOt in each year.
The research in this paper provides a technical and theoretical basis for coal gangue, tailings, and low-grade limestone for cement clinker calcinations.
引文
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