年产20万吨矿渣微粉生产线的工艺设计及设备选型 

is responsible for Organization training, and implementation, and check; 12, master workshops annual economic indicators of implementation, reporting to financial health on a regular basis; 13, is responsible for the daily oversight in the allocation and use of funds; 14, responsible for all Department statistics, collecting, sorng, reporting of accounting reports; 15, the company responsible for the supervision of the Treasury, including the \d grade\ library, a library of materials, products for regular inventory handling, sampling, storage monitoring, the picking work, and provide the inventory report, and make the appropriate accounting treatment; 16, responsible for waste and recycling, transportation and settlement; 17, is responsible for all product sales accounting functions; 18, responsible for the company's raw materials, auxiliary materials, account management; 19, is responsible for the flow of control of all assets of the company, according to the changes in accounting treatment offixed assets and assets to the departments responsible for clearing, settlement and asset monthly report submitted to the asset management section of the Finance Department of the company organized on a company-wide special inspection of asset management; 20, according to the company's business activities, monthly projects involved in the business activities of the company (including expenses, business management, cost control, cash flow, revenue, etc) financial analysis, provide a basis for decisions for the company, the business of the company responsible for monitoring, forecasting and risk analysis; 21, responsible for the settlement of transactions with the Bank; 22, is年产20万吨矿渣微粉生产线的工艺设计及设备选型

概述

高炉矿渣是钢铁厂高炉炼铁的副产品，经水淬急冷处理后，呈浅灰色玻璃晶体颗粒状，属于工业废渣材料.长期以来被直接作为水泥混合材使用.由于矿渣比水泥熟料易磨性差，在通常的水泥粉磨后所含矿渣的粒度比水泥的粒度粗很多，矿渣的活性得不到充分发挥.粗粒度的矿渣在水泥水化过程中仅起到微集料的填充作用.近几年经过大量细致的实验研究，将矿渣研磨成高比表积、高细度、使其改性成为具有潜在的胶凝性材料的可能已变成现实，其在碱性条件下活性能够得到充分发挥，使混凝土和水泥的多项性能得到了极大的改善和提高. 1. 工艺设计方案的确定

1．1设计概况：由于水淬矿渣具有高含水量，易磨性差等特点，单独粉磨矿渣微粉难度较大，一直处于产量低、电耗高，入机矿渣水分难以去除状态.近年来随着高效节能烘干技术、高细高产管磨设备的不断研制开发，使得高细度、高比表积的矿渣微粉的工业化生产已成为可能.合肥水泥研究院粉磨研究所利用成熟技术及设备已设计投产十多条矿渣微粉生产线，形成低成本经济性工艺设计方案；其中主要技术指标如表1所示。

表1 年产20万吨超细矿渣粉磨各项技术参数 ≤1.0% 流动度比（%） ≥95 入料综合水分 入料粒度 ≤5.0mm 活性指数（%） 7d:95 产品比表面积 400～420m2/Kg 28d:105 系统产量 ≥11.5t/h×2=23t/h*2台 系统运转率 ≥80% 系统总装机功率 2020KW 粉磨系统电耗 65kwh/t

图1 江苏省江阴华西混凝土有限责任公司工艺流程图

is responsible for Organization training, and implementation, and check; 12, master workshops annual economic indicators of implementation, reporting to financial health on a regular basis; 13, is responsible for the daily oversight in the allocation and use of funds; 14, responsible for all Department statistics, collecting, sorting, reporting of accounting reports; 15, the company responsible for the supervision of the Treasury, including the \d grade\y, a library of materials, products for regular inventory handling, sampling, storage monitoring, the picking work, and provide the inventory report, and make the appropriate accounting treatment; 16, responsible for waste and recycling, transportation and settlement; 17, is responsible for all product sales accounting functions; 18, responsible for the company's raw materials, auxiliary materials, account management; 19, is responsible for the flow of control of all assets of the company, according to the changes in accounting treatment offixed assets and assets to the departments responsible for clearing, settlement and asset monthly report submitted to the asset management section of the Finance Department of the company organized on a company-wide special inspection of asset management; 20, according to the company's business activities, monthly projects involved in the business activities of the company (including expenses, business management, cost control, cash flow, revenue, etc) financial analysis, provide a basis for decisions for the company, the business of the company responsible for monitoring, forecasting and risk analysis; 21, responsible for the settlement of transactions with the Bank; 22, is1.2工艺系统流程及生产线布置

矿渣微粉生产工艺仍然分为开路和闭路二种，其中在设备选择及产品综合技术指标上都有所区别，本文所述为开流工艺粉磨系统。 （１）经济实用的开路高细管磨系统

采用开路高细管磨工艺，具有生产工艺简单，系统产品质量和品种可调性强，易于布置和易于生产设备管理及土建投资少，建设工期短 特点.例如：江苏省江阴市华西混凝土有限责任公司，年产20万吨矿渣微粉生产线，从设计到投产试车仅用4个月时间.生产线顺畅，布局简便合理，如图1所示。 （２）物料平衡计算及各种物料储存量和储存期表

表2 年产20万吨超细矿渣所需原材料表 物料 名称 水 配合比分 （%） % 物 料 平 衡 （t） 干 料（t） 湿 料（t） (h) (d) (a) (h) (d) （a） 备注 96 24 576 29.63 711.12 4 1 24 300 1.04 24.96 7488 100 25 600 18Kg/t 0.432 10.368 3110.4 0.465 11.16 3348 矿渣 20 石膏 5 超细矿渣 煤 8 磨系统运转率：82 %（300天）

表3 各种物料储存量和储存期表 序号 1 2 3 4 物料名称 储存方式 规格（m） 湿矿渣 干矿渣 石膏 超细矿渣 堆棚 圆库 圆库 圆库 30×120 Φ10×26 Φ5×15 Φ10×26 数量 1 2 1 6 储量（t） 储期（天） 2300 800 200 3200 4 1.5 10 5.8 2、设备选型及合理应用 2．1设备选型

根据生产线工艺流程，湿矿渣先运至原料堆棚堆放，再送入烘干系统进行烘干处理，在入库储存；而石膏经破碎机破碎后入石膏库储存.如需增加粉煤灰，可设粉煤灰库底配料.该几种物料经库底皮带秤计量后，由皮带机直接送入高细管磨中，经粉磨后的成品——矿渣微粉由提升机运至成品库中储存，并通过库底或库侧散装机送入散装汽车，或由空气斜槽（或FU、螺旋输送机等）送至码头由船只运输出厂.各主要设备如表四所示：

（一）矿渣烘干系统设备

is responsible for Organization training, and implementation, and check; 12, master workshops annual economic indicators of implementation, reporting to financial health on a regular basis; 13, is responsible for the daily oversight in the allocation and use of funds; 14, responsible for all Department statistics, collecting, sorting, reporting of accounting reports; 15, the company responsible for the supervision of the Treasury, including the \d grade\y, a library of materials, products for regular inventory handling, sampling, storage monitoring, the picking work, and provide the inventory report, and make the appropriate accounting treatment; 16, responsible for waste and recycling, transportation and settlement; 17, is responsible for all product sales accounting functions; 18, responsible for the company's raw materials, auxiliary materials, account management; 19, is responsible for the flow of control of all assets of the company, according to the changes in accounting treatment offixed assets and assets to the departments responsible for clearing, settlement and asset monthly report submitted to the asset management section of the Finance Department of the company organized on a company-wide special inspection of asset management; 20, according to the company's business activities, monthly projects involved in the business activities of the company (including expenses, business management, cost control, cash flow, revenue, etc) financial analysis, provide a basis for decisions for the company, the business of the company responsible for monitoring, forecasting and risk analysis; 21, responsible for the settlement of transactions with the Bank; 22, is表4 序号 1 2 3 4 5 6 7 8 名 称 高效节能烘干机 （专利新产品） 节煤型高温沸腾炉 抗结露耐高温 玻纤袋式收尘器 系统引风机 变频调速皮带秤 系统电控柜(M) 移动式空压机 提升、输送设备 型号规格（m） HR24—Φ2.4×18 HRP24 LFEF4×358 Y5—48NO12.5C TDGV—1000 2.2×0.8×0.6 V1.0/7 数量（台） 装机功率（Kw） 1 1 1 1 1 2 1 按工艺而定 45 68 10 55 1.1 15 （二）矿渣粉磨系统设备 表5 序号 1 2 3 4 5 名称 高细高产管磨机 气箱脉冲袋式收尘器 移动式空压机 系统引风机 提升、输送设备 型号规格（m） 数量（台） 功率（Kw） Φ2.4×13 TGM64—5 W2.58/5 Y5—48NO8C 2 800×2=1600 2 8.5×2=17 2 15×2=30 2 15×2=30 按工艺要求而定 （三）石膏破碎、配料及散装系统设备 表6 序号 1 2 3 4 5 6 7 8 名称 细颚破碎机 袋收尘器 收尘风机 变频调速皮带秤 库底散装装置 库底散装收尘器 收尘风机 提升、输送设备 型号规格（m） PEX—250×1200 LFX（II）4—14 数量（台） 功率（Kw） 1 1 37 1.5 6—30NO7C 1 7.5 TDGV—800 4 3.5×4=14 SZ—1 4 3.3×4=13.2 LFX(II)4—14 2 1.5×2=3.0 6—30NO7C 1 7.5 按工艺要求而定 2．2所选设备的合理使用

由于矿渣微粉在磨内粉磨过程中会产生大量热量，易使原料矿渣中的水分溢出，造成糊球、结团现象，严重影响粉磨效率及电耗，因此入磨矿渣的含水量对其粉

is responsible for Organization training, and implementation, and check; 12, master workshops annual economic indicators of implementation, reporting to financial health on a regular basis; 13, is responsible for the daily oversight in the allocation and use of funds; 14, responsible for all Department statistics, collecting, sorting, reporting of accounting reports; 15, the company responsible for the supervision of the Treasury, including the \d grade\y, a library of materials, products for regular inventory handling, sampling, storage monitoring, the picking work, and provide the inventory report, and make the appropriate accounting treatment; 16, responsible for waste and recycling, transportation and settlement; 17, is responsible for all product sales accounting functions; 18, responsible for the company's raw materials, auxiliary materials, account management; 19, is responsible for the flow of control of all assets of the company, according to the changes in accounting treatment offixed assets and assets to the departments responsible for clearing, settlement and asset monthly report submitted to the asset management section of the Finance Department of the company organized on a company-wide special inspection of asset management; 20, according to the company's business activities, monthly projects involved in the business activities of the company (including expenses, business management, cost control, cash flow, revenue, etc) financial analysis, provide a basis for decisions for the company, the business of the company responsible for monitoring, forecasting and risk analysis; 21, responsible for the settlement of transactions with the Bank; 22, is磨效果十分敏感，故在现有工艺系统中，要求严格控制入磨矿渣水分低于0.5～1.0%.而对于采用高细高产磨粉磨矿渣微粉而言，要想达到高细度、高比表面积、高低电耗的效果，磨机结构参数及工艺参数的确定起着决定性的作用，即磨内仓位的设置、隔仓板、出料篦板、衬板及研磨体级配的选择是否合适，都会通过台时产量、产品细度、比表面积反映出来.同时也直接影响到矿渣微粉成品颗粒级

配，江苏省江阴华西混凝土有限责任公司工艺参数选择如表7所示。 表7

15-20% 入机水分 出机水分 0.5-1.2% 台时产量 45-48t/H 单位煤耗 16-18Nkg/t 废气排放 ≤50mg/Nm3 入磨粒度 ≤5.0 mm 隔仓板形式 3种 比表面积 420m3/kg 衬板形式 5种 台时产量 12-14t/h 研磨体级配 Φ16×18/Φ8×8 系统电耗 58-65Kwh/t 活化衬板 4～5圈 磨机仓位3仓 球料比 5.2-5.7 设置 3、工艺设计的合理性及成功案例 3．1工艺设计的合理性及分类 3.1.1工艺设计的合理性

矿渣微粉生产线厂址的选择一般是根据原料来源较近、靠近水路运输或距离中心城市较近等特点来选择。通常，在厂区内为达到最大的有效使用空间，对工艺布置的合理性要求较高，既要考虑现有的生产能够正常需要，还要能够从长远发展的角度来对现有场地进行预留下一步扩展的配置空间。如图2所示, 江苏南通九华矿渣微粉有限公司为适应将来扩建而在现有设计过程中所做的统筹考虑。

随着我国水泥企业上大改小方针的进一步落实，将会有许多靠近城市的立窑水泥企业被迫关停或 改造成粉磨站、或生产矿渣微粉，所以合理有效地利用原有厂房、设备资源,是降低投资的首选。安徽省合肥恒利建材有限公司（合钢矿渣微粉厂）就是在利用原合肥第二水泥厂停产磨房、生料库及输送设备基础上建成的；在场地条件允许的情况下，尽量考虑单层平面厂房布置，从而使土建投资及设备安装、维护管理费用降到最低。 3.1.2生产工艺的种类及应用 （1）技术先进型：

a．江苏省江阴市绮星水泥有限公司：

is responsible for Organization training, and implementation, and check; 12, master workshops annual economic indicators of implementation, reporting to financial health on a regular basis; 13, is responsible for the daily oversight in the allocation and use of funds; 14, responsible for all Department statistics, collecting, sorting, reporting of accounting reports; 15, the company responsible for the supervision of the Treasury, including the \d grade\y, a library of materials, products for regular inventory handling, sampling, storage monitoring, the picking work, and provide the inventory report, and make the appropriate accounting treatment; 16, responsible for waste and recycling, transportation and settlement; 17, is responsible for all product sales accounting functions; 18, responsible for the company's raw materials, auxiliary materials, account management; 19, is responsible for the flow of control of all assets of the company, according to the changes in accounting treatment offixed assets and assets to the departments responsible for clearing, settlement and asset monthly report submitted to the asset management section of the Finance Department of the company organized on a company-wide special inspection of asset management; 20, according to the company's business activities, monthly projects involved in the business activities of the company (including expenses, business management, cost control, cash flow, revenue, etc) financial analysis, provide a basis for decisions for the company, the business of the company responsible for monitoring, forecasting and risk analysis; 21, responsible for the settlement of transactions with the Bank; 22, is

工艺线路：矿渣烘干→挤压机→打散机→选粉机（细粉）→高细磨→成品；

b.江苏省南通九华矿渣微粉有限公司（30万吨/年低能耗，高比表面积）： 工艺线路：矿渣烘干机→（预留挤压机）→高细高产磨→成品； （2）低能耗环保型：

1. 北京上联首丰建材厂（15万吨/年）：

工艺线路：矿渣烘干机（节煤性高温沸腾炉,燃烧焦炭渣,SO2和NOX均低于国标,抗结露玻纤袋式收尘器，废气排放≤50mg/Nm3）→高细磨（气箱脉冲袋式收尘器，废气排放≤50mg/Nm3） →成品（各点加设收尘器）； 1. 江苏省江阴华西矿渣微粉有限公司：

工艺线路：矿渣烘干机（节煤性高温沸腾炉,燃烧焦炭渣,SO2和NOX均低于国标,抗结露玻纤袋式收尘器，废气排放≤50mg/Nm3）→高细高产磨（气箱脉冲袋式收尘器，废气排放≤50mg/Nm3） →成品； （3）经济实用型：

1. 江苏省南京市滨江微粉科技有限公司（15万吨/年）： 工艺线路：矿渣烘干机→高细磨→成品；

b．浙江省湖州市天泽利矿渣微粉有限公司（10万吨/年）： 工艺线路：矿渣烘干机→高细磨→成品； （4）原有立窑水泥厂改造型：

1. 安徽省合钢公司水泥厂（8万吨/年）：

工艺线路：改造原有烘干系统（干渣水分≤1%）→改造磨机系统（比面积≥400）→成品；

1. 浙江省杭州高强微粉有限公司（8万吨/年）：

工艺线路：改造原有烘干系统（干渣水分≤1%）→改造磨机系统（比面积≥400）→成品；

c．河北省唐山市永基建材厂（8万吨/年）

工艺线路：矿渣烘干机（干渣水分≤1%）→高细磨（比面积≥400）→成品 3．2低成本工艺设计的成功案例

近几年来，我们先后在浙江、江苏、安徽、北京、上海、河北等省市采用低成本经济型工艺设计方案，建成十几条矿渣微粉生产线，均取得良好的生产效果.如表8所示： 表8