Under the high pressure of environmental protection, cement enterprises are pursuing the firing system to increase the clinker output of single machine as much as possible in unit time. At the same time, taking various new technical measures to reduce the coal consumption of unit clinker firing has become an important direction of long-term sustainable development of enterprises.

According to industry insiders, the original thermal insulation material of cement kiln firing system is calcium silicate board or ceramic fiber board, which has high thermal conductivity. In order to further improve the thermal insulation effect of cement thermal equipment, the application of new nano thermal insulation material can achieve the purpose of expanding volume and saving energy. At present, many cement enterprises began to use nano thermal insulation materials. From the application effect of some cement enterprises, the thermal insulation performance of nano materials is much better than that of traditional thermal insulation materials, which can save more energy in the case of the same thermal insulation thickness.

As a leader in the domestic nano thermal insulation material industry, Nanjing Ziyang New Material Technology Co., Ltd. (hereinafter referred to as "Nanjing Ziyang") independently developed, produced and sold the zit nano thermal insulation material to replace the traditional thermal insulation material calcium silicate board. In terms of performance, the thermal insulation effect is four times that of calcium silicate board, which can reduce the heat consumption and coal consumption of thermal equipment, In the cement industry firing system has also been very obvious verification. Today, cement internal reference will show you the application effect of nano thermal insulation materials of Nanjing Ziyang in Ruifeng cement and Wangyang Jianbao cement of xingchuancheng group.

1、 2500t calciner of Ruifeng cement, Panzhihua, xingchuancheng group

After years of operation, the shell temperature of Ruifeng cement calciner is too high, the average temperature can reach 145 ℃ (local high temperature can reach 190 ℃), the heat insulation effect is very poor, resulting in a lot of heat loss, reducing the thermal efficiency of the calciner.

Ruifeng cement attaches great importance to the energy-saving transformation of the sintering system. Knowing that other cement plants of the group have better heat insulation effect by using zit nano heat insulation material, Ruifeng cement has a detailed communication with Nanjing Ziyang on the heat insulation application of the calciner, and finally decides to carry out the heat insulation application in the lower straight section of the calciner. In the lower straight section of calciner, the 115mm calcium silicate board is replaced by 40mm zit950 nano thermal insulation material. The use area is 150m² and the effective volume is expanded by 9.83m³. The ignition will be started on September 14, 2019.

In order to verify the performance of zit nano thermal insulation material, Ruifeng cement applied 70mm thickness calcium silicate board in the same part of calciner for comparison. The specific comparison results are shown in the following TABLE-1

Structure and effect of refractory lining of decomposition furnace - 1

It can be seen from the above that the shell temperature of calciner is reduced by 35 ℃ on average by using 40mm zit950 nano thermal insulation board compared with 70mm calcium silicate board.

Before the maintenance and reconstruction of precalciner, the shell temperature of the old fire-resistant and heat-insulating structure was tested, and the detailed comparison is shown in table-2.

 Comparison of new and old refractory lining of precalciner-2

The 40mm zit950 nano thermal insulation board is used to replace the 115mm calcium silicate board, and the inner diameter is expanded by 150mm. Compared with the old 115mm calcium silicate board, the shell temperature is reduced by 75 ℃ on average.

2、 Xingchuancheng group Jianbao cement 3200t grate cooler

Xingchuancheng Jianbao Cement Co., Ltd. has used nano thermal insulation materials from Nanjing Ziyang in the five stage cyclone and flue gas chamber, both of which have achieved excellent thermal insulation effect of relatively reducing 50 ℃. Therefore, nano thermal insulation materials will continue to be used in the maintenance and transformation of grate cooler this time.

        Before the grate cooler is repaired and rebuilt, the shell temperature test of the old fire-resistant and heat insulation structure was carried out. See table-3 for detailed comparison.  

Effect table of grate cooler refractory lining heat insulation transformation-3

It can be seen from the table above that, on the basis of the reduction of one side wall thickness by 120mm, the temperature of shell can be reduced by 50-80 ℃ by using ceramic fiber and zit nano insulation materials.

3、 Conclusion:

  From the above application effect, the cement industry sintering system adopts zit nano thermal insulation material, which not only meets the demand of capacity expansion, but also greatly reduces the equipment shell temperature, thus reducing the heat loss and coal consumption to a certain extent.

  Nanjing Ziyang products have been widely used in southern cement, Hongshi cement, Jinyu cement, Jidong Cement, conch cement, etc., and more than 100 digit customer equipment have been widely used, and the products and application technology are very mature. It can be predicted that in the future, with the extensive application of this new nano separator, it can make its own unique contribution to the energy saving and consumption reduction of cement industry.