回转窑热平衡计算.xls

生料浆成分Al2O3Na2OkCaOSiO2组分含量211.43112.03321.86150.39其中：液体成分36.2357.390.47其中：固体成分175.254.64321.86149.92蒸发水量熟料量211.43112.03321.86150.39比热kcal/(kg)0.2050.22密度g/cm33.93.25-3.382.32分子量102625660组分mol2.0731.8075.7482.507反应热(kcal)69.67283.040生生料料浆浆量量(kg)(kg)：2073.51生生料料含含水水量量(kg)(kg)：887.05熟熟料料量量(kg)(kg)：1186.46氧氧化化铝铝回回收收率率：85%烧烧结结反反应应Al2O3(晶)+Na2CO3=Na2OAl2O3+CO2(气)H298(kJ/mol)：SiO2(晶)+2CaO=2CaOSiO2 H298(kJ/mol)：Fe2O3+Na2CO3=Na2OFe2O3+CO2(气)H298(kJ/mol)：TiO2+CaO=CaOTiO2 H298(kJ/mol)：Fe2O3+C=2FeO+CO H298(kJ/mol)：熟熟料料烧烧成成用用煤煤成成分分煤类别Vdaf(%)Car(%)Har(%)Oar(%)Nar(%)无烟煤72.24.269.350.79熟料烧成用煤燃烧所需理论空气量(kg/kg)：Vo=0.115(Car+0.375Sar)+0.342Har-0.431Oar(kg/kg)Vo(m3/kg)7.266空气过剩系数a1.3Vo(kg/kg)5.769空气过剩系数a1.3固体燃料烟气生成量(m3/kg)：Vy=VCO2+VSO2+VH2O+VO2+VN2VCO2=0.01866*Car1.347VSO2=0.007*SarVH2O=0.111*Har+0.0124*Mar+0.00124*VnVO2=0.21*(a-1)*Vn0.458VN2=0.008N2ar+0.79Vn烟气密度(kg/m3)：y=(1.964VCO2+0.804VH2O+2.857VSO2+1.25VN2+1.429VO2)0.01VCO2=VCO2/Vy(%)13.771VH2O=VH2O/Vy(%)VSO2=VSO2/Vy(%)0.064VN2=VN2/Vy(%)VO2=VO2/Vy(%)4.679生生料料掺掺煤煤成成分分煤类别Vdaf(%)Car(%)Har(%)Oar(%)Nar(%)无烟煤74.82.237.290.76熟料烧成用煤燃烧所需理论空气量(kg/kg)：Vo=0.115(Car+0.375Sar)+0.342Har-0.431Oar(kg/kg)Vo(m3/kg)7.216空气过剩系数a1.3Vo(kg/kg)6.504空气过剩系数a1.3固体燃料烟气生成量(m3/kg)：Vy=VCO2+VSO2+VH2O+VO2+VN2VCO2=0.01866*Car1.396VSO2=0.007*SarVH2O=0.111*Har+0.0124*Mar+0.00124*VnVO2=0.21*(a-1)*Vn0.455VN2=0.008N2ar+0.79Vn烟气密度(kg/m3)：y=(1.964VCO2+0.804VH2O+2.857VSO2+1.25VN2+1.429VO2)0.01VCO2=VCO2/Vy(%)14.540VH2O=VH2O/Vy(%)VSO2=VSO2/Vy(%)0.476VN2=VN2/Vy(%)VO2=VO2/Vy(%)4.736熟熟料料烧烧结结生生成成废废气气成成分分(m3)(m3)CO2O2N2H2O生料掺煤成分(m3)36.31511.827192.9637.462烧成用煤成分(m3)140.21147.641777.27652.366生料烧结成分(m3)104.575887.050空气湿度(g/m3)1.370空气带入水(m3)1.681合计(m3)281.10159.468970.23861.510比热(kcal/m3/)(245)0.440.3220.3110.364生料浆进料温度：80废气温度：液体比热：kcal/kg/0.8废废气气带带走走热热：液体质量：kg942.1窑灰:干生料固体比热：kcal/kg/0.2出窑灰量：固体质量：kg1131.41窑灰比热：生生料料浆浆带带入入热热：kcal78396.96出窑灰温度：窑灰比热：kcal/kg/0.273窑窑灰灰带带走走热热：烟道收尘率：%60%化化学学反反应应吸吸热热：烟道收尘量：kg891.756熟料量：烟道入收尘温度：240熟料出料温度：旋风收尘率：%91.8%熟料比热：旋风收尘量：kg545.755熟熟料料带带走走热热：旋风入收尘温度：168机机械械不不完完全全燃燃烧烧热热：电收尘率：%98.2%散热损失：电收尘量：kg47.872窑窑壳壳散散热热：电入收尘温度：40蒸发水量：窑窑灰灰带带入入热热：kcal83981.106水比热：二次风分配量：%70%水沸腾吸热：二次风量：kg700.343水汽排放温度：二次风温度：250水汽比热：二次风比热：kcal/kg/0.24水汽吸热：二二次次风风带带入入热热：kcal42020.56399水汽化热：一次风分配量：%20%水汽化吸热热：一次风量：kg200.098蒸蒸发发水水分分吸吸热热：一次风温度：47烧成用煤量：一次风比热：kcal/kg/0.24生料掺煤占燃料的比例：一一次次风风带带入入热热：kcal2257.105生料掺煤量：漏风分配量：%10%总配入煤量：漏风量：kg100.049煤比热：漏风温度：30入煤温度：漏风比热：kcal/kg/0.24煤煤带带入入热热量量：漏漏风风带带入入热热：kcal720.353煤煤燃燃烧烧发发热热量量：1186.46kg1186.46kg熟熟料料回回转转窑窑热热平平衡衡热热收收入入热热支支出出项目kJkcal%项目煤粉燃烧发热量864944.47380.484废气带走煤粉带入热量2354.1090.219窑灰带走料浆带入78396.967.295蒸发料浆水分窑灰带入83981.1067.815孰料带走二次风带入42020.563993.910机械部不完全燃烧一次风带入2257.1050.210化学反应吸热漏风带入720.3530.067窑壳散热合计1074674.669100合计1t1t熟熟料料回回转转窑窑热热平平衡衡热热收收入入热热支支出出项目kJkcal%项目煤粉燃烧发热量729012.75580.484废气带走煤粉带入热量1984.1450.219窑灰带走料浆带入66076.361617.295蒸发料浆水分窑灰带入70782.9227.815孰料带走二次风带入35416.755723.910机械部不完全燃烧一次风带入1902.3860.210化学反应吸热漏风带入607.1440.067窑壳散热合计905782.470100合计1tAO1tAO回回转转窑窑热热平平衡衡热热收收入入热热支支出出项目kJ103kcal%项目煤粉燃烧发热量4812854.05880.484废气带走煤粉带入热量13099.0850.219窑灰带走料浆带入436228.14957.295蒸发料浆水分窑灰带入467300.2937.815孰料带走二次风带入233817.13873.910机械部不完全燃烧一次风带入12559.3210.210化学反应吸热漏风带入4008.2940.067窑壳散热合计5979866.339100合计Fe2O3TiO2CO2Na2Oc其他45.4327.63206.6439.2571.8005.237.82045.4327.63201.4131.4371.845.4327.63206.6439.2571.80.2630.1650.20.24941.9762.53216080801060.2840.3452.5839.7347.163生生料料浆浆含含水水率率：0.428干干生生料料量量(kg)(kg)：生生成成氧氧化化铝铝量量(kg)(kg)：179.716固固定定碳碳量量:干干生生料料量量(kg)(kg)：吸吸热热140.7138.68143.586.82-40.58Sar(%)Aar(%)Mar(%)Qarnet(kcal/kg)理论燃烧空气量(Nm3/kg)0.91.5006667.467.284实际空气量Vn：9.446实际空气量Vn：7.500Vy(m3/kg)9.7830.0060.5037.469y(kg/m3)1.3355.14376.342熟熟料料烧烧成成用用煤煤成成分分熟料烧成用煤燃烧所需理论空气量(kg/kg)：Vo=0.115(Car+0.375Sar)+0.342Har-0.431Oar(kg/kg)烟气密度(kg/m3)：y=(1.964VCO2+0.804VH2O+2.857VSO2+1.25VN2+1.429VO2)0.01Sar(%)Aar(%)Mar(%)Qarnet(kcal/kg)理论燃烧空气量(Nm3/kg)6.532.2306574.247.228实际空气量Vn：9.380实际空气量Vn：8.456Vy(m3/kg)9.5990.0460.2877.417y(kg/m3)1.3572.98877.260合计248.5671017.494104.5751.6811372.317245kcal114406.8881.200kg1486.26kcal/kg/0.273245生生料料掺掺煤煤成成分分熟料烧成用煤燃烧所需理论空气量(kg/kg)：Vo=0.115(Car+0.375Sar)+0.342Har-0.431Oar(kg/kg)烟气密度(kg/m3)：y=(1.964VCO2+0.804VH2O+2.857VSO2+1.25VN2+1.429VO2)0.01废气温度：废废气气带带走走热热：窑灰:干生料出窑灰量：窑灰比热：出窑灰温度：kcal99408.5001kcal169.610kg1186.46900kcal/kg/0.26kcal277631.64kcal20758.66736kcal/t-熟料1792kcal2126.13632kg887.05kcal/kg/1kcal17741245kcal/kg/0.5kcal64311.125kcal/kg539kcal478119.95kcal560172.075kg104.072%0.2kg26.018kg130.09kcal/kg/0.31258kcal2354.109kcal864944.4734kJkcal%114406.88810.64699408.5009.250560172.07552.125277631.6425.83420758.667361.932窑窑灰灰带带走走热热：化化学学反反应应吸吸热热：熟料量：熟料出料温度：熟料比热：熟熟料料带带走走热热：机机械械不不完完全全燃燃烧烧热热：散热损失：窑窑壳壳散散热热：蒸发水量：水比热：水沸腾吸热：水汽排放温度：水汽比热：水汽吸热：水汽化热：水汽化吸热热：蒸蒸发发水水分分吸吸热热：烧成用煤量：生料掺煤占燃料的比例：生料掺煤量：总配入煤量：煤比热：入煤温度：煤煤带带入入热热量量：煤煤燃燃烧烧发发热热量量：1186.46kg1186.46kg熟熟料料回回转转窑窑热热平平衡衡热热支支出出项目废气带走窑灰带走蒸发料浆水分孰料带走机械部不完全燃烧169.6100.0162126.1360.1981074673.517100kJkcal%96427.09210.64683785.8009.250472137.345552.12523400025.83417496.306121.932142.9540.0161792.0000.198905781.498100kJ103kcal%636600.00510.646553143.7199.2503116993.66552.1251544839.70525.834115508.49741.932943.7670.01611830.5670.1985979859.926100化学反应吸热窑壳散热合计1t1t熟熟料料回回转转窑窑热热平平衡衡热热支支出出项目废气带走窑灰带走蒸发料浆水分孰料带走机械部不完全燃烧化学反应吸热窑壳散热合计1tAO1tAO回回转转窑窑热热平平衡衡热热支支出出项目废气带走窑灰带走蒸发料浆水分孰料带走机械部不完全燃烧化学反应吸热窑壳散热合计结晶水附水总计52.09834.962073.51834.96942.152.0901131.41887.05887.051186.46111846.387169.6101238.551.571物质Al2O3Al2O3Al2O3H2OAl2O33H2O AlCl36H2O状态c()c()cccH298（kcal/mol）-400.4-396-478-610.1-643.3物质NH4FBaCO3BaOBaSO4CaCO3状态cccccH298（kcal/mol）-110.89-290.7-131-352.1-288.45物质CaSO4CaSO42H2OCaSiO3CaSiO3Ca2SiO4状态c(可溶）ccamorpc(）H298（kcal/mol）-339.58-483.42-389.2-382.65-551.5物质H2OH2SO4FeOFe2O3Fe3O4状态gliqcccH298（kcal/mol）-57.796-194.55-65-197-267.3物质MgSO4H2OMgSO46H2OMgSO47H2OK2OSiF4状态ccccgH298（kcal/mol）-382.9-737.8-809.92-86.8-385.98物质Na2CO3H2O Na2CO310H2ONa2ONaOHNa2SO4状态cccccH298（kcal/mol）-342.08-975.46-99-101.72-331.52物质TiO2TiO2TiO2CO2(NH4)2SiF6状态c(锐钛矿)c(板钛矿)c(金红石)gcH298（kcal/mol）-224.36-225.1-225.8-94-640.94AlCl3AlF3AlF33H2OAl(OH)33CaOAl2O33CaOAl2O3cccccamorp-168.65-361-549.1-307-857.5-849CaOFe2O32CaOFe2O3CaOCa(OH)2CaSO4CaSO4ccccc(不可溶）c(可溶）-363.37-511.3-151.8-235.7-342.76-340.64Ca2SiO43CaOSiO23CaO2SiO2CaTiO33CaO2TiO2H2Oc(）ccccliq-554-700.1-946.7-396.9-944.2-68.315FeSO4FeSO4FeSO47H2O Fe2(SO4)3Fe2(SO4)3MgOcaqccaqc-221.9-236.6-720.5-617-675.2-142.92SiO2SiO2NaAlO2NaAlO2Na2CO3Na2CO3camorpcaqcaq-217.27-215.94-271.3-277-270.26-276.62Na2SO410H2ONa2SiO3SO2SO2SO3SO3ccliqgliq9-1034.24-371.68-76.6-70.944-105.41-94.58Al2(SO4)3COaqg-906-26.42表表1 1 几几种种铝铝酸酸盐盐生生料料浆浆的的组组成成（摘摘录录红红皮皮书书208208页页）生料浆特征固体部分组成%Al2O3Na2OCaOSiO2Fe2O3TiO2+SO3+P2O5铝土矿石灰石苏打生料24.722.58.44.69.65.7铝土矿苏打（两成分）生料26.827.32.92.511.25.6赤泥石灰石苏打生料12.51123912.5/铝土矿石灰苏打生料25.616.7714.97.73.423.53混联法生料22.4818.1216.887.953.066.1霞石石灰石苏打生料11.67.432.617.32.21.5表表2 2 孰孰料料窑窑烟烟气气含含尘尘量量和和收收尘尘效效率率（摘摘录录红红皮皮书书212212页页）地点含尘浓度收尘效率%收尘量t/h烟气流速g/m3g/Nm3g/Nm3(dry)Nm/s垂直烟道进口228.544182560.0433.872.45垂直烟道出口149287.6287.62.95旋风收尘器进口81.6146.8723.9791.7820.7311.2-12.3旋风收尘器出口6.712.0819.366.2-6.4电收尘室进口6.711.8418.7698.191.940.6-0.66电收尘室出口0.1220.2150.316表表3 3 孰孰料料窑窑热热工工测测定定的的部部分分数数据据（摘摘录录红红皮皮书书218218页页）作业带名称烘干带预热分解带烧结带冷却带位置（距离窑尾）m0-1010-5757-6767-72.4长度m1047105.4占窑长%13.86513.87.4占窑面积%14.3262.3514.938.4炉料温度（进）6917010801350炉料温度（出）170108013501120窑气温度（进）60014501500535窑气温度（出）389.760014501500表表4 4 孰孰料料窑窑的的特特性性数数据据和和产产能能（摘摘录录红红皮皮书书219219页页）编号炉料铝土矿、炉料铝土矿、赤泥炉料霞石炉料(流入法)赤泥炉料铝土矿炉料燃料原油煤粉重油煤粉天然气窑长m73.310018510070外径m4.3/3.84553.6窑长平均内径19.126.74021.721.9内表面面积m2883117026001445704容积m3845.71097/转速rpm21.831.61.852斜度%4232.52热交换器面积m265.32603080/热力强度106kcal/m2h27/6.935.263.79热力强度106W/m2h31.4/8.076.114.41废气温度230180-220230300315单产kg/m2h49.5736.438.445.437.1产量t/h43.7742.510065.526.1燃料种类燃烧方式(空气过量系数)人工加煤 机械化加煤空气与燃料自动比例调节空气与燃料人工比例调节喷射式烧嘴煤、焦炭1.2-1.51.2煤粉1.2-1.25液体燃料1.151.2-1.25气体燃料1.05-1.1 1.15-1.2 1.05-1.1水分含量%粒度+80微米含量%生料浆密度kg/m3灼减27.836.11023.733.410198024.540.51117002740.125.539.5170026.530101760温度m/s4.73260-2405.320-22210-18011.2-12.31.02-1.11 160-145红皮书222页提到：窑的热功率Q(W)与窑的内径D内(m)有关，经验式Q=(2.8-3)*D内2.5*106，知道了熟料热量单耗q，即可求出窑的小时产能B=Q/q。但窑的产能还受到熟料生成条件的限制，在烧结Fe2O3含量较高的铝土矿和赤泥炉料的情况下要求B/D内8的数值不超过950kg/m3h，在烧结霞石炉料时不大于1250kg/m3h，根据红皮书219页得到有关窑长和平均内径的参数如下：窑长m10073.370100185外径m44.3或3.83.655窑长平均内径26.719.121.921.740平均内径m3.7453.8383.1964.6084.625表表1 1 几几种种铝铝酸酸盐盐生生料料浆浆的的组组成成（摘摘录录红红皮皮书书208208页页）烟气流速表表5 5 碱碱石石灰灰铝铝土土矿矿孰孰料料窑窑热热平平衡衡数数据据（摘摘录录红红皮皮书书220220页页）项目104kJ104kcal%项目104kJ原油燃烧318.77876.14649.21废气带走101.528生料掺煤燃烧176.76642.22429.23窑灰带走25.211原油显热2.1880.530.34蒸发料浆水分255.496料浆带入31.577.5414.88孰料带走142.099窑灰带入21.3765.1063.3机械部不完全燃烧7.305二次风带入83.55619.95912.9化学反应吸热72.395一次风及漏风带入0.9250.2210.14窑壳散热43.714合计647.749154.727100合计647.749表表6 6 各各主主要要反反应应发发生生的的温温度度和和热热性性质质（摘摘录录氧氧化化铝铝生生产产工工艺艺240240页页）温度()反应热性质100游离水蒸发吸热500放出结晶水（铝土矿）吸热Al2O3H2O=Al2O3+H2OAl2O32SiO22H2O=Al2O32SiO2+H2O900CaCO3=CaO+CO2吸热800-1250熟料矿物的形成放热Al2O3+Na2O=Na2OAl2O3Fe2O3+Na2O=Na2OFe2O3SiO2+2CaO=2CaOSiO2红皮书222页提到：窑的热功率Q(W)与窑的内径D内(m)有关，经验式Q=(2.8-3)*D内2.5*106，知道了熟料热量单耗q，即可求出窑的小时产能B=Q/q。但窑的产能还受到熟料生成条件的限制，在烧结Fe2O3含量较高的铝土矿和赤泥炉料的情况下要求B/D内8的数值不超过950kg/m3h，在烧结霞石炉料时不大于104kcal%24.25215.676.0223.8961.0339.4433.94321.941.7451.1317.29311.1810.4426.75154.727100热效应2251kJ/kgH2O820kJ/kgAl2O3933kJ/kg1657kJ/kg1402kJ/kg1105kJ/kg690kJ/kg