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Chng 1 : Tng qut chung v sn xut xi mng

1. Cng ngh sn xut xi mng Poolng

1.1. Cc khI nim v sn phm xi mng pooclng : Xi mng l cht kt dnh thu lc cng trong nc v khng kh, c to ra bi vic nghin chung clinke vi thch Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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cao v mt s ph gia khc. Clinke l thnh phn quan trng nht ca xi mng, quyt nh tnh cht ca xi mng. Nguyn liu chnh sn xut clinke l vi (CaO) v st (SiO2, Fe2O3, Al2O3). Cht lng ca clinke ph thuc vo thnh phn ho hc v thnh phn khong ca n. Thnh phn ho hc ca clinke c biu din bng t l thnh phn cc xt trong phi liu v l ch tiu quan trng kim tra cht lng clinke. Tng hm lng 4 xt c bn: CaO, SiO2, Fe2O3, Al2O3 trong clinke chim t l t 95 98%, tnh cht ca clinke v xi mng ph thuc ch yu vo t l ca cc xt c bn ny. T l hm lng cc xt trong clinke thng th ng nh sau: CaO 63 - 67% SiO2 21 - 24% Al2O3 4 - 7% Fe2O3 2 - 4 % vo

Bng vic thay i t l hm lng cc xt c bn ny khi cp my nghin ta c th thay i tnh cht ca xi mng. Ngoi cc xt c bn trong clinke cn c cc xt khc nh : MgO, Na2O, P2O5,MnO2 Trong qu trnh nung luyn clinke bn xt c bn trn s tc dng vi nhau to thnh cc khong xc nh tnh cht ca xi mng. Trong xi mng c cc khong chnh nh sau : Silicat 3 Canxi (Alit) Silicat 2 Canxi (Bezit) Aluminat 3 Canxi Alumoferit 4 Canxi khong sau : Silicat 3 Canxi (Alit) (42 - 60)%
2

3 CaO.SiO2 2 CaO.SiO2 3 CaO.Al2O3 4 CaO.Al2O3.Fe2O3

Hm lng cc khong c bn trong clinke nm trong cc

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Silicat 2 Canxi (Bezit) (15 - 50)% Aluminat 3 Canxi Alumoferit 4 Canxi (2 - 15)% (10 - 25)%

Ngoi cc phi liu c bn trn cn c cc ph gia c a vo phi liu nung hoc nghin cng clinke nhm tng cng hoc hn ch mt s tnh cht no ca xi mng: - Ph gia khong lm xc tc cho nhng phn ng ha hc, sau khi hon thnh s nm li lun trong sn phm. - Ph gia iu chnh dng iu chnh s kt dnh v ng rn ca xi mng, thng dng thch cao. - Ph gia thy lm tng tnh bn nc ca xi mng. C 2 loi: + Dng t nhin: tro ni la, bt. + Dng nhn to: x ca nh my luyn kim, x l caovv - Ph gia in y: nhm tng sn lng xi mng, gim ga thnh sn phm. - Ph gia bo qun: c tc dng to mng ngn m bao bc cc ht xi mng, ngn khng cho chng ht m, thng dng du thc vt du lc c phn tn cao. Xi mng l cht kt dnh xy dng, cc thnh phn ho hc ca n gm cc hp cht c baz cao. Trn quan im ho hc ngi ta phn chia nh sau : - Nhm xi mng Silc Mi trng nc. - Nhm xi mng Alumin Mi trng nhit cao. - Nhm xi mng khc Mi trng c bit. Xi mng Pooclng l cht kt dnh thu lc c sn xut bng cch nghin mn clinke xi mng vi thch cao (3 5%) v ph gia (nu c). Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Xi mng Pooclng hn hp l sn phm nghin mn ca hn hp clinke, thch cao (3 5%) vi ph gia hn hp (tng lng khng ln hn 40%, trong ph gia y khng ln hn 20%). Khi thnh phn trng lng ph gia thm vo > 15% th xi mng c gi theo tn gc cng vi tn ph gia nh xi mng Pooclng x, xi mng Pooclng pudlan Clinke xi mng l sn phm nung n kt khi ca hn hp nguyn liu vi, t st theo cc mul h s ph hp to c cc thnh phn khong theo mong mun. H s bo ho vi : LSF =
100.C 2,8.S + 1,18. A + 0, 65.F

i vi xi mng Pooclng thng (LSF = 95 100%). Mul Silc : SIM =

S A+ F

i vi xi mng Pooclng (MS = 1,7 3,5). Mul nhm : ALM =

A F

i vi xi mng Pooclng (MA = 1 3). Trong : (C, S, A, F) l % cc xt CaO, SiO 2, Al2O3, Fe2O3 trong clinke. Thnh phn khong (% khi lng) xi mng Pooclng thng : Khong Alit C3S hm lng 45 60%. Khong Blit C2S hm lng 20 30%. Khong Alumin canxi C3A hm lng 5 15%. Khong Alumferit canxi C4AF hm lng 10 18%. Pha thu tinh, hm lng t 15 30%. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Thnh phn ho hc : Cc xt chnh gm : CaO, SiO 2, Fe2O3, Al2O3 chim t 95 97%, cn li t 3 5% l cc xt khc (Na 2O, K2O, MgO, Mn2O3, SO3, TiO2). Xi mng Pooclng thng cc xt nm trong gii hn : - CaO = 63 67%. - SiO2 = 21 24%. - Al2O3 = 4 7%. - Fe2O3 = 2,5 4% - R2O < 1,5%. - TiO2 < 5%. - MnO2 < 1,5%. - MgO 5%. 1.2 . Nguyn liu sn xut xi mng : Thnh phn phi liu sn xut ra clinke gm bn xt chnh l CaO, SiO2, Al2O3, Fe2O3. + xt canxi do nhm nguyn liu cacbonat canxi cung cp. + xt SiO2, Al2O3, Fe2O3 nm trong cc khong st do t st cung cp. + iu chnh cc mul cho hp l ta phi thm vo mt s ph gia iu chnh nh Diantomit, qung st, bxt. a. Nhm nguyn liu cha CaO : to ra CaO : CaCO3 Ca(OH)2
700 C 1000 C
o o

CaO + CO2

CaO + H2O

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Trong Ca(OH)2 l tt nht v c phn tn cao, hot tnh. Khi chn nguyn liu nu c vi st m hm lng st > 20% l tt nht . Cho clinke tt, cng ngh n gin, t tn nng lng. b. Nhm nguyn liu cha SiO2, Al2O3, Fe2O3 : t st cha cc thnh phn sau : - Khong st. - Mui khong. - Tp cht hu c. - , si, ct, trng thch. Trong khong st l ch yu. sn xut xi mng th t st phi c hm lng khong st > 70 75%. Trong khong caolinit l ch yu. Khi t l mul, h s cha hp l ta phi dng cc cu t ph gia giu SiO2, Al2O3, Fe2O3 iu chnh. 1.3. Nhin liu nung clinke xi mng : Qu trnh to khong clinke xi mng thu nhit v ch xy ra hon ton nhit cao 1400 1500 0C trong thi gian nht nh. V vy, phi cung cp nhin liu nung chn c clinke. Trong cng ngh sn xut xi mng hin ang s dng 3 loi nhin liu chnh sau : - Nhin liu rn (Than) - Nhin liu lng (Du MFO) - Nhin liu kh (Kh thin nhin) a. Nhin liu rn : Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Hin nay cc nh my xi mng ch yu dng loi than la di, nhiu cht bc pha hn hp than bi hoc than Atraxit phn loi theo s cm 1, 2, 3 ,4, 5 lm nhin liu. Yu cu ca than dng trong l quay : - Nhit tr : QH 5500 Kcal/kg than. - Cht bc : V = 15 30%. Yu cu k thut ca than dng trong l ng : - Nhit tr : QH 5500 Kcal/kg than. - Cht bc : V < 20%.

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b. Nhin liu lng : Du MFO nhit nng cao, t tro, d iu chnh khi nung nhng gi thnh cao gp 2 3 ln than v phi gia nhit trc khi phun vo l (90 1000C). Du MFO s dng lm nhin liu cho sn xut xi mng phi tho mn nhng yu cu k thut sau : - Nhit lng 9200 Kcal/Kg du. - Lng nc ln 1%. - T trng 200C 0,98 Tn/m3. - Hm lng lu hunh 2,1%. c. Nhin liu kh : Dng kh thin nhin rt sch, d iu chnh, khng c tro, dng sn xut xi mng trng rt tt. S dng khng phi gia cng. 1.4. Cc phng php sn xut xi mng : Cc yu cu k thut ca phi liu : - m bo thnh phn ho. - m bo mn ( 15% trn sng R 008). - m bo m . - m bo ng nht. Phn loi cc phng php sn xut xi mng : Theo chun b phi liu : 1- Phng php t : phi liu vo l dng bn c m W = 36 42% 2- Phng php kh : phi liu vo l dng bt c m W = 1 2% 3- Phng php bn kh : phi liu vo l dng vin c m W = 12 14%. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Ba phng php ny ch khc nhau c bn khu gia cng v chun b phi liu nung. Theo h thng l : 1. H thng l ng. 2. H thng l quay (l quay phng php t hoc l quay phng php kh). la chn phng php sn xut hp l, nh sn xut phi da vo mt s iu kin sau : - Vn u t. - Quy m sn xut. - Mt bng sn xut. - Ngun nguyn, nhin liu. - Trnh trang thit b sn xut. T nhng iu kin thc t m ngi ta la chn phng php sn xut hp l. Hin nay, cc nh my xi mng hin i ch yu s dng l quay phng php kh. 1.5. Qu trnh ho l xy ra khi nung clinke trong l quay : Qu trnh din bin khi nung tri qua 8 giai on din bin theo s sau. Theo chiu mi tn th qu trnh xy ra i t u l, ni nguyn vt liu vo n cui l clinke ra l. (Giai on vit tt l G) G1 Mt nc l hc, t0 1000C. G2 Mt nc ho hc phn hu khong caolinit (khong st), t0 = 600 9000C. G3 Phn hu magi cacbonat (MgCO3) , t0 = 7000C. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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G4 Phn hu canxi cacbonat (CaCO3), t0 = (9000C 10000C). G5 Phn ng pha rn xy ra qu trnh khuych tn b mt, khuych tn th tch. To cc khong clinke nhit thp v cc khong trung gian, t0 > 6000C. G6 Xut hin pha lng do cc khong d nng chy. Qu trnh khuych tn ho tan CaOtd, C2S qu bo ho kt tinh ra C3S do tng tc ca CaOtd v C2S. G7 Lm lnh clinke t 14500C xung 11000C. G8 Clinke ra khi gin lm lnh nhit t 1100 0C xung 800C. Cc giai on ny c tch ra ch l tng i nhm phn nh qu trnh c bn nht m khong nhit to ra. Gia cc giai on c tnh cht lin tc, phn ng hay qu trnh din ra cui giai on ny th l u ca giai on tip theo. Din bin ca cc giai on c trnh by nh sau : G1 Mt nc l hc, khong nhit khong 1000C. G2 Mt nc ho hc phn hu khong caolinit (khong st), t0 600 9000C. Tch nc ho hc, nc lin kt trong cu trc khong Al2(OH)4.[SiO5]. T 600 9500C Al2O3.2SiO2.2H2O Al2O3 vdh + SiO2 vdh Al2O3 vdh , SiO2 vdh tn ti dng t do. G3 Phn hu magi cacbonat (MgCO3), t0 = 7000C. MgCO3 10000C). CaCO3
700 C 1000 C
o o o

700 C

MgO + CO2

G4 Phn hu canxi cacbonat (CaCO 3), t0 = (700 CaO + CO2

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G5 Xy ra phn ng pha rn (t 0 > 6000C). Hnh thnh cc khong C2S, C3A, C4AF. Phng trnh phn ng : C+F C+A 3CA + 2C 2C + S C + CF C5A3 + 4C C3A + CF
500 600 C
o o

CF

800 900 C CA >900 C

o o

C 5 A3

900 1000 C C2S 900 1000 C C2F

o

>1200 C 3C3A
o

>1200 C

C4AF

G6 Xut hin pha lng 12500C 14500C. Cc khong C3A, C4AF, mui kim loi kim nu c nng chy to ra pha lng v ng thi l qu trnh ho tan C 2S, CaOtd hot tnh, tinh th khng hon chnh ho tan khuych tn. Khi nng vt qu nng bo ho th tng tc nhanh gia C2S v CaO to mm v kt tinh ra C3S. Vng phn ng kt khi, pha lng xut hin do cc khong d chy nh C3A, C4AF v mt s mui ca h cht kim nng chy. Cc khong C2S, CaOtd khuych tn vo pha lng. Cc ht ny ho tan dn vo pha lng, khi vt qu nng bo ho th c xu hng kt tinh to ra C3S. Qu trnh ny ph thuc vo nhit , nht ca pha lng, nng ca cht khuych tn trong pha lng, hot tnh ho hc ca C 2S v CaOtd. Qu trnh kt tinh ng ngha vi qu trnh lm mt trng thi bo ho nng C 2S v CaOtd ho tan trong lng gim. Do qu trnh ho tan li tip tc. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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mi nhit c mt nng bo ho nht nh. Khi lm lnh nhit gim th qu trnh kt tinh tinh th C 3S tng ln, tinh th C3S ln ln. Khi gim nhit ti < 1300 0C th C3A, C4AF, C2S ti kt tinh. Tuy nhin pha lng vn tn ti v tn ti cht ho tan. Do vy kt tinh tinh th C 3S vn c tip tc ng thi vi qu trnh ln ln ca tinh th. Tc khuych tn ph thuc c bit vo nhit , bn cht ca C2S v CaOht. G7 Lm lnh clinke, gim nhit t 14500C 11000C. Cc qu trnh giai on ny xy ra : a. C kh nng phn hu mt phn C3S nhit < 12000C. C3S C2S + CaOtd Nhng do lm lnh nhanh trong khong nhit 12500C v do C3S to dung dch rn vi cc xt khc ln bn v t b phn hu. b. Pha thu tinh hnh thnh c cc xt t do MgO, CaO phn tn trong pha thu tinh. c. Kt tinh v pht trin C3S, ti kt tinh C2S, C4AF kt tinh t C3S t pha lng thu tinh. G8 Lm lnh t 11000C xung 800C. C cc qu trnh ch yu sau xy ra : - Kt tinh C3S v ti kt tinh C2S. - Bin i th hnh ca C2S c bit phi lm lnh nhanh trong khong nhit 675 0C v : C2S C2S xung

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Trnh hin tng bin i C2S sang C2S. Duy tr c hm lng C2S c tnh kt dnh v ng rn to cng cho xi mng. 1.6. Qu trnh gia cng v bo qun clinke xi mng : a. Gia cng clinke xi mng : * clinke : Nhit clinke ra khi my lm lnh khong 100 1500C khng th a vo my nghin ngay c v : Nhit cao thch cao s b mt nc bin thnh thch cao khan CaSO4.0,5H2O + 1,5H2O gy nn hin tng ninh kt gi. Trong clinke cn c hin tng CaO t do v MgO t do s gy ra tc hi khng n nh th tch xi mng, hay sinh nt n cu kin xy dng. Hn na, lc nghin s va p c nng bin thnh nhit nng lm cho my nng, gim tui th my nghin. Do , clinke ra l bt buc phi trong sil t 7 15 ngy nhm mc ch : + clinke ht m khng kh lm cho CaO Ca(OH)2 n th tch pht sinh vt nt rn trong clinke. Vt nt cng su, ng sut ni trong vin clinke cng ln dn n clinke dn d nghin p. Nng sut my nghin tng, hao mn tm lt, bi n t. + Tip tc lm lnh clinke xung gn nhit thng trc khi nghin. + Clinke dn, d nghin hn. * Nghin clinke xi mng : CaSO4.2H2O
t C
o

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nghin xi mng cc loi ngi ta thng dng my nghin bi nhiu ngn hoc nghin ng chu trnh kn c h thng phn ly trung gian thu hi sn phm nghin mn, trnh hin tng bt xi mng t mn yu cu cn b nghin li lm gim lm gim kh nng nghin ca bi n. Trong qu trnh nghin p, c nng bin thnh nhit nng. Nhit xi mng thnh phm phi c khng ch trong khong 1100 1250C m bo khng lm mt tc dng ca thch cao, khng xy ra s vn kt kh trong my nghin, nh hng n nng sut my nghin. Mt trong nhng bin php tch cc l bm lm mt bn trong my nghin. Vic bm nc c th thc hin 2 u my nghin. Bn cht cc khong clinke nh hng ti nng sut nghin : + cng ln nht kh nng nghin km nht l C2S sau l C4AF. D nghin nht l khong C3S nghin trung bnh l khong C3A. Tu loi nguyn liu, ch nung, ph gia khong ho, s bin i th hnh ca khong C2S trong clinke lm gin, cng clinke hon ton khc nhau. Clinke nhiu khong Alt nghin d hn khong Blt c ngha h s bo ho vi LSF tng th clinke d nghin. + Nu mul nhm cao hn 1,5 to nn clinke rt xt c v c cng rt ln do rt kh nghin. b. Bo qun clinke xi mng :

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Clinke ra l phi c a vo sil cha v bo qun. Vic bo qun ny c nh hng tt n cht lng xi mng v nng sut my nghin xi mng. Clinke lu ngoi tri, cht lng s b suy gim ng k v nc ma ra tri cc khong ca clinke theo nc, cc ht clinke nh v b mt cc vin clinke ln tip xc vi nc v khng kh m ng rn s b. Khi ng rn s b thnh nhng tng khi rn chc s gy kh khn ln cho cng vic vn chuyn v bc xc. Do , khi lu clinke ngoi tri cn che y cn thn. Trc khi a vo nghin phi kim tra cht lng. Khi nghin clinke lu ngoi tri, nng sut my nghin thp v: - Kch thc ht vo nghin ln - m clinke cao, linh ng ca vt liu km dn n bt t. Sn phm nghin mn b li Blaine cao v st sng cao. 1.7. Qu trnh ng rn v hyrt ho ca xi mng : Qu trnh ho hc gm hai giai on : G1 Xi mng tc dng vi nc cho cc sn phm ca phn ng thu phn hoc hyrt ho. G2 Gm cc phn ng th cp, cc sn phm ca phn ng s cp tc dng tng h nhau hoc tc dng vi cc phn hot tnh ca ph gia to cc khong mi, lm tng cng ca xi mng. * Xt khong C3S (Alt): Cho phn ng thu phn tu hm lng vi trong pha lng : Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Nng vi CaO < 0,08g/l. C3S + H2O 3Ca(OH)2 + SiO2.nH2O Nng vi CaO = 0,08g/l. 2C3S + H2O 2CSH(B) + Ca(OH)2 Nng vi CaO = 1,1g/l. 2C3S + H2O C2SH2 + Ca(OH)2 Trong iu kin thc t th C3S phn ng qua cc giai on sau: C3S C2SH2 + Ca(OH)2 CSH(B) Trong : C2SH2 l vit tt ca cng thc sau : xCa(OH)2.SiO2.yH2O vi x = 1,7 2,0 y = 2,0 4,0 CSH(B) l vit tt ca cng thc sau : xCa(OH)2.SiO2.yH2O vi x = 0,8 1,5 y = 0,5 2,5 * Xt khong C2S (Blt): Blt l khong ch yu thu ho khi hyrt ho C2S s thu phn nu nhiu nc v lc lin tc phng trnh phn ng C2S + nH2O 2Ca(OH)2 + SiO2.(n - 2)H2O Nhng trong iu kin thc t th C 2S khng thu phn m ch to ra cc gen C 2SH2, CSH(B), khng to ra Ca(OH)2. C2S + nH2O C2SH2 CSH(B)

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Cc hyr silicatcanxi CSH(B) l cht ch yu to ln tnh kt dnh m bo cho xi mng pht trin cng v bn vng. * Xt khong C3A, C4AF(Alumilatcanxi, Alumoferitcanxi): Khong C3A tc dng rt nhanh vi H 2O to pha trung gian l C4AHx vi (x = 13 - 19). Sn phm cui cng l C3AH6. Phng trnh phn ng hyrat ho ca khong C3A, C4AF : 4C3A + 45/2H2O 3C4AH14 + AH3 AH3 + 3CH C4AF CaO.Fe2O3.H2O CaO.Fe2O3.H2O + 2Ca(OH)2 + xH2O C3FH6 Do cu trc ca tinh th C 3A l xp v rt hot tnh nn khong C3A tc dng rt nhanh vi nc do h xi mng s nhanh chng lin kt v ng rn v gy kh khn cho vic thi cng trong sn xut thc t. khc phc ngi ta dng thch cao iu chnh thi gian ca hyrat ho C 3A. Khi C3A hyrat ho xung quanh ht C3A c nhiu in Al3+ Khi ho tan vo nc th xung quanh ht thch cao c nhiu in SO42- . Thch cao s tc dng vi C 3A, H2O to ra cc khong sau : + Hyro trisunfo Aluminat Canxi : Cng thc ho hc l C3A.3CaSO4.3H2O
t C
o

C3AH6
H 2O

C3AH6 +

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+ Hyro monosunfo Aluminat Canxi : Cng thc ho hc l C3A.CaSO4.12H2O Trn b mt xung quanh ht C3A do bo ho in Al3+ v t in SO42- khuych tn t thch cao sang v hnh thnh khong monosunfo Aluminat cu trc hnh vy tm, lp cu trc ny to mng sn phm. Mng sn phm ny c chc nng hn ch in Al3+ t ht C3A khuych tn ra b mt. Trn b mt xung quanh ht thch cao th nng Al 3+ khuych tn t C3A sang l t do vy n bo ho in SO 42- to nn sn phm trisunfo Aluminat. Khong ny cu trc hnh kim ri ni v xp do cho php SO 42- khuych tn d dng hn v khuych tn qua b mt ht C3A. Khi xung quanh ht C3A bo ho SO42- th khong hyro trisunfo Aluminat Canxi li hnh thnh v cho php Al 3+ khuych tn ra. Nhng do qu trnh khuych tn Al 3+ ra b mt qua cu trc xp nhanh hn qu trnh khuych tn SO42- t ht thch cao sang do khong Hyro trisunfo Aluminat Canxi li hnh thnh to mng sn phm bao bc ht C3A v hn ch lm chm s hyrat ho ca C3A. Nu thiu thch cao th khng iu chnh c thi gian ng kt. Cn nu tha thch cao th tc dng ngc li. Do vy, lng thch cao cho vo xi mng phi va v hp l, lng t (3 5%) l ph hp. * Xt s hyrat ho ca pha thu tinh : Khi hyrat ho vi nc, kim tan v i vo pha lng li cc gc khong v chng phn ng, hyrat ho nh cc khong chnh C3A, C4AF, C3S. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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1.8. Mt s tnh cht ca xi mng : 1.8.1 - mn. 1.8.2 - Khi lng th tch. 1.8.3 - Trng lng ring (khi lng ring). 1.8.4 - S gim cng khi bo qun ( gim mc lc lu kho). 1.8.5 Lng nc tiu chun ( do tiu chun). 1.8.6 Thi gian ng kt. 1.8.7 Tnh chu la. 1.8.8 Mc ca xi mng. 1.8.9 - n nh th tch. 1.9. Cc loi ph gia a vo nghin xi mng : Ph gia iu chnh thi gian ng kt ca xi mng. Ph gia tr nghin. Ph gia thu hot tnh. Ph gia y (ph gia li). Ph gia bo qun.

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2. Quy trnh sn xut xi mng ti cng ty xi mng Hong thch

Qu trnh sn xut xi mng c cc trnh t thao tc cng ngh sau : - Khai thc nguyn liu. - Nghin liu. - ng nht liu. - Nung luyn thnh clinke. - Nghin clinke vi ph gia. - ng bao. Di y l s dy chuyn cng ngh sn xut xi mng Pooclng v xi mng Pooclng hn hp ti Cng ty xi mng Hong Thch :

Sinh vin thc hin: Hong Minh Sng Lp KT2 K46

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 n tt nghip

st

p ba

Cn trc

p ba

vi

Silc iu chnh

Kho ng nht s b

Kho Qung st Bxit Ph gia Thch cao Than

Cp qung st-bxit

Sy-nghin liu

Sy-nghin than

ng nht

B du

Hm sy du

Than mn

Cp liu l

L quay S lan du

Kt ph gia

Kt thch cao

Sil cha clinke

ng bao

Sil xi mng

Nghin xi mng

ng b

ng thu

ng st

Nh my xi mng Hong Thch c 2 dy chuyn : dy chuyn I (HT I) v dy chuyn II (HT II). Hai dy chuyn hot ng song song vi nhau. Do dy chuyn II i vo hot ng mun hn so vi dy chuyn I nn cng ngh v thit b tin tin hn dy chuyn I. V vy trong n Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
21

 n tt nghip

ny ch yu trnh by cng ngh v thit b sn xut xi mng dy chuyn II. Nh my xi mng Hong Thch bao gm 4 phn xng tng ng vi trnh t thao cng ngh sn xut xi mng, l cc phn xng : - Phn xng nguyn liu. - Phn xng l nung. - Phn xng xi mng. - Phn xng ng bao. 2.1. Phn xng nguyn liu : Khi qut v cng ngh : Phn xng nguyn liu bao gm t cc my gia cng nguyn liu th n gia cng nguyn liu tinh v ng nht tinh bt liu. Gm cc my p ba gia cng vi, my p ba gia cng st, my gia cng ph gia cho nguyn liu cho n cc kho ng nht s b. Cng on gia cng nguyn liu tinh gm cc my nghin bi, bt liu sau my nghin bi c a vo cc xil ng nht ca hai dy chuyn, l cc xil F-F (dy chuyn I) v xil CF (dy chuyn II). a. Dy chuyn II : vi c khai thc bng cch khoan n mn ct tng. vi sau cng on n mn c gia cng p s b vi nhng hn c kch thc ln hn 1500 mm, sau c xc ln xe ti t R32 ri vn chuyn v phu cp liu cho my ba A2M01 (EV 200*300 thuc cng trnh 11 cho dy chuyn II) qua bng xch J10. Nng sut my ba EV 200*300 l 1000 (t/h), cng sut Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
22

 n tt nghip

my ba l 1200 (KW). Kch thc vt liu vi vo my p ba 1200 (mm), vt liu sau my ba c kch thc 25 (mm) khng qu 5%. Vt liu t kch thc lt qua ghi ra liu i xung cc bng ti vn chuyn gm cc bng (A2J12, A2U1) ti van chia U11 (c th cp mt phn cho dy chuyn I). Vt liu t van chia U11 c chuyn tip vo cc bng ti (U12, U02), bng ti A2J01 a vo ri lung trong kho ng nht s b 15A2, vi c ri theo phng php ri lung v ri thnh hai ng (A, B), th tch mi ng 10600 (m 3). Mi ng c s lng l 24 lung, s lp l 8 lp. vi sau khi c ri ng nht s b th c gu xc R2L03 ly liu theo mt vt nghing t nhin ca ng nh lng bi cn in t v vo bng ti hn hp R2J07. st c khai thc bng phng php khoan n mn, i, gt, xc ln thit b vn chuyn t R32, Euclit, vn chuyn v phu cp liu cho my p ba hai trc C1M01 qua bng ti xch J01 thuc cng trnh 13. My ba c cng sut l 110 (KW), nng sut my ba l 210 (t/h). Kch thc st vo my p ba 800 (mm) xung bng ti xch, vt liu t kch thc i qua ghi sng sau my p ba c kch thc 75 (mm). Sau vt liu chuyn xung bng ti J02 ti cc bng tip theo gm (J03, J04) i vo my cn hai trc M02. My cn hai trc gm 2 rul cn hnh tr c vu vi nng sut my cn l 210 (t/h). Kch thc vt liu vo l kch thc liu sau my ba hai trc C1M01, kch thc liu ra l Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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 n tt nghip

25 (mm), vi lng ln hn khng qu 5%. Vt liu sau my cn hai trc i vo cc bng ti vn chuyn gm (J05, J06, J07). Ti bng ti J06 c hai ca , mt i vo dy chuyn I, mt i vo dy chuyn II. Liu t ca ti dy chuyn II i vo bng ti R2U01 v ti bng ti J01 vo ri lung ng nht s b. st c ri thnh hai ng (A, B), th tch mi ng l 4700 (m 3), s lung l 24, s lp l 18. vi v t st sau khi c ng nht s b th c nh lng cp vo my nghin tinh bt liu. m bo cht lng clinke, ta phi kim sot theo ng m un, h s xc nh. Do ngoi vi v t st cn c cc nguyn liu iu chnh ln lt l qung st (giu hm lng xt Fe2O3) v bauxit (giu hm lng Al2O3). Qung st v bauxit c nhp v qua cng thuc cng trnh 23, c vn chuyn v ri ng trong kho 26. Qung st v bauxit ln lt c chuyn vo phu cp liu i xung cc bng ti J01, J02, ti bng ti J02 c ca i vo bng ti R2U15 v bng hai chiu R2U16 ti cc kt cha (R2L01, R2L02) cp liu cho my nghin. Qung st v bauxit t hai kt cha ring bit c nh lng bng 2 cn simat A01, B01 ri tho xung bng ti cao su l R2U18 v R2U17 vo bng ti hn hp R2J08. Hn hp vt liu t bng R2J08 i vo bng ti R2J09 cp liu i vo my nghin R2M01.

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 n tt nghip

Liu t u ra ca my nghin bao gm hn hp liu mn v liu cn th cng vi kh sau sy. Hn hp liu mn v kh sau sy i trc tip ln phn ly SEPAX S01, hn hp liu mn v th hn c i xung mng kh ng R2M22 chuyn vo gu nng R2J01 vo mng kh ng R2J02 chuyn vo phn ly SEPAX S01. Phn ly SEPAX S01 c chc nng tch ra ht mn thu hi , ht th hi lu li my nghin. Ht th hi lu li my nghin qua van nn v mng kh ng J04 xung cn in t xc nh lng liu hi lu. Ht mn cng vi kh i vo 2 cyclone lng R2S15 v R2S17, ti y liu mn lng xung vo hai van xoy S16, S18 xung mng kh ng R2U01, van chia R2U06 vo mt trong hai gu nng R2A20 hoc WB20. Liu mn vo chn gu nng R2A20 th tip tc c i xung mng kh ng R2A21 vo xil ng nht tinh bt liu (xil CF H01). Liu vo chn gu W2B20 i ln v vo mng R2A20 ti van ct dng W2A24 xung mng R2A21 i vo xil ng nht tinh bt liu H01. Ti xil CF H01 bt liu c ng nht v tho liu lin tc ti nhiu im, nhiu lp khc nhau trong th tch ton xil. Vi chu trnh tho t ng qua 42 im trong 7 ca ca 3 nhm. Nhm 1 gm cc ca (A, B), nhm 2 gm cc ca (C, G), nhm 3 gm cc ca (E, D, F). Chu k tho mi im ca cc nhm 1 v 2 l 60 giy cn cc im thuc nhm 3 l 45 giy. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
25

CF

 n tt nghip

Liu c tho xung hp gom H23, ti y c cp mt phn cho dy chuyn I qua kt cn W2A11 cp liu l I. Phn ch yu cp liu cho l II qua kt cn W2A01, mng W2A06 v mt trong 2 gu nng W2A20, W2B20. Kh thi tch bi mn ti 2 cyclone lng (S15, S17) c ht bi qut S20 c cng sut 1800 (KW) qua van iu chnh gi R2R01. Kh thi t qut S20 mt phn hi lu tr li phn ly R2S01 qua van iu chnh R2R02, phn cn li c y vo lc bi in J2P21 qua van J10 cng vi kh thi ca l II. Kh sch sau lc bi in c ht bi qut P27 qua van tm P26 y vo ng khi i ra ngoi. b. Thnh phn ho v h s, mul ca bt ch to v bt np vo l : + Bt liu ch to : Thnh phn Thng s H s, mul : LSF = 93 107 SIM = 2.0 2.6 ALM = 0.7 2.0 + Bt liu np l : C h s, mul nh sau : LSF = 99 0.1 SIM = 2.5 0.05 Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
26 12 14
2.0 4.0

SiO2

Al2O3

Fe2O3

CaO

(W)

m St sng 0,09%
12%

1,8 4.0

42 46

1.0%

 n tt nghip

ALM = 1.5 0.05 2.2. Phn xng l nung : (xem chng 2). 2.3. Phn xng xi mng : Clinke, thch cao, ph gia qua h thng bng ti, gu nng, cn simat c vn chuyn ti my nghin lm vic theo chu trnh kn c h thng phn ly v lm mt trc tip bng nc t 2 u my nghin, khi ht th mt ng nng quay tr li my nghin, ht mn c a ln cyclone lng thu hi ht mn, qua h thng bng ti a vo kt cha, mt phn xi mng c mang i xut ri, mt phn a sang phn xng ng bao. Dy chuyn II : Clinke c gu nng W2J27 v bng ti xch W2J14 vn chuyn vo kt cha Z2L06 c cn simat cng vi thch cao, ph gia c ly t kho 26 qua h thng bng ti Z2U22 vo 2 kt cha Z2L07 v Z2L08 c cn simat nh lng t ng cp liu vo my nghin v t l t % ca clinke, thch cao, v ph gia. My nghin xi mng trong dy chuyn II l my nghin loi TUMS c kch thc 5.9*16 m lm vic theo chu trnh kn (c phn ly trung gian kiu Sepax 425M- 22), c h thng phun nc lm mt t 2 u my nghin, my nghin c nng sut thit k l 200 (t/h), cng sut ng c 680 KW. Bt liu ra khi my nghin qua h thng mng kh ng Z2M22, gu nng Z2J01 a vo h thng phn ly Sepax, y ht th mt ng nng ri xung mng kh ng Z2J08 quay tr li my nghin, ht mn thi ln 4 cyclone lng Z2S15, S17, S19, S21 ri lng xung mng kh Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
27

 n tt nghip

ng, qua h thng vt ti Z2U01, U02, U03, U06, U07, U08, qua h thng mng kh ng U10, U14 a vo 5 sil cha P1L01, L02, L03, L04, L05 ch ng bao hoc xut xi mng ri. 2.4. Phn xng ng bao : Tng quan v quy trnh cng ngh xung ng bao : S cng ngh dy chuyn Hong Thch I:

Xi l cha xi mng Mng kh ng Vt ti

Gu nng Sng quay Kt cha

Vt ti

Xi mng thu hi

My ng bao Bng ti xut xi mng

Sinh vin thc hin: Hong Minh Sng Lp KT2 K46

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 n tt nghip

Dy chuyn ng bao Hong Thch I c dy chuyn cp liu hon ton nh nhau, trn y ch l s chung cho mt dy chuyn. Xi mng cha trong sil (1, 2, 3) c tho qua 8 ca tho. Nguyn tc tho l dng kh nn sc vo y sil, gi ho lng xi mng, xi mng c chuyn qua cc knh mng kh ng vo vt vn chuyn. iu chnh xi mng ra bng cch iu chnh lng kh nn sc vo hoc bng van chn c kh. Xi mng c vt ti chuyn n gu nng, gu nng vn chuyn xi mng ln cao theo phng thng ng, xi mng c vo sng thng quay ti y thc hin vic loi b cc tp cht c kch thc ln hn 10 x 20, nhng ht t tiu chun c a vo kt cha cp liu cho my ng bao nh mt h thng van cp liu cho my ng bao. Sau khi ng bao xong cc bao xi mng c vn chuyn nh h thng bng ti vn chuyn i xut xi mng. Lng xi mng thu hi t bunker my ng bao qua mt ng dn thng ng xung vt thu hi tr li gu nng. Dy chuyn ng bao Hong Thch II c s ging nh Hong Thch I ch khc l xi mng tho t sil xung mng kh ng c vn chuyn trc tip ti gu nng khng nh vt ti nh Hong Thch I. Gu nng Hong Thch II s dng gu bng ti cn Hong Thch I s dng gu xch. Mt im khc bit na trn s dy chuyn l Hong Thch II s dng sng rung loi b tp cht thay v s dng sng quay nh s ng bao Hong Thch I.

Sinh vin thc hin: Hong Minh Sng Lp KT2 K46

29

 n tt nghip

Xi mng ca dy chuyn I c cha vo 3 sil 1 ,2 ,3 (P1L01, P1L02, P1L03) cn dy chuyn II c cha vo cc sil 4 ,5 (P1L04, P1L05). Dy chuyn ng bao 1 c su my ng bao FluxoRU12 N01, N02, N03, N04, N05, N06 c cp liu t 3 sil 1, 2, 3, mi ca ch c 2 my ng bao lm vic. Xi mng t cc my ny c cp cho c ng b v ng thu. Dy chuyn ng bao 2 ch c 2 my ng bao VENTOMATIC P2N01 v P2N02 ly t hai sil 4, 5 ch dng xut ng thu. Ngoi xut xi mng ng bao cn xut c xi mng ri. Tuyn xut xi mng ri cho t : xi mng c tho t sil N03 qua h thng knh mng kh ng vo kt cha P1L06 chun b cho vic xut xi mng bt. Tho xi mng ra khi kt cha P1L06 thng qua van chn c a vo ng kh ng P1C05 vo ng trt P1C06 xut cho t. Tuyn xut xi mng ri cho ng thu : xi mng c ly t hai ngun - T kt cha P1L06 qua ng P1B07 vo vt ti P1U02. - T cc sil P1P04, P1L05 tho qua cc ca tho liu vo vt ti hai chiu P1U01 sau vo vt ti P1U02 ti mng ti cao su c vn chuyn ra cng thu.

3. Gii thiu cng ngh v thit b sn xut xi mng ca nh my xi mng Hong Thch
- Cng ty xi mng Hong Thch l mt n v thnh vin ca tng cng ty xi mng Vit Nam, nm ti a bn Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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 n tt nghip

x Minh Tn, huyn Kinh Mn, tnh Hi Dng, cch th H Ni 100km. - Cng ty xi mng Hong Thch c 2 dy chuyn sn xut theo phng php kh vi tng cng sut 2,3 triu tn xi mng/nm. + Dy chuyn 1 cng sut 1,1 triu tn/nm. Hot ng t thng 11/1983. + Dy chuyn 2 cng sut 1,2 triu tn/nm. Hot ng t thng 5/1996. - Vi cng ngh v thit b tin tin vo loi nht th gii ca hng F.L.Smidth (an Mch). C hai dy chuyn hc mc cao t sn xut c t ng ho v tin

khu phi liu, nung luyn clinke n nghin v ng bao xi mng thng qua chng trnh c lp trung tm x l vi tnh v iu hnh hai phng iu khin trung tm. Nh vy, sn phm xi mng Hong Thch lun n nh vi cht lng cao, c khch hng tn nhim. - Ngoi cc chng loi xi mng pooc-lng truyn thng nh PC30, PC40, cng ty cn sn sut cc chng loi xi mng c bit nh xi mng bn sunfat, xi mng dng cho cc ging khoan su v trung bnh - Dy chuyn 1 cng sut thit k 1,1 triu tn clinke/nm, l quay vi h thng sy s b 4 tng cyclone trao i nhit. Thit b hin i ca hng F.L.Smidth (an Mch), sau hn 10 nm sn xut vn hot ng n nh, t cng sut thit k.

Sinh vin thc hin: Hong Minh Sng Lp KT2 K46

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- Dy chuyn 2 bt u hot ng t thng 5/1996, thit b vo loi tin tin nht th gii ca hng F.L.Smidth (an Mch), cng sut thit k 1,2 triu tn clinke /nm. L quay c h thng sy s b vi 1 dy 5 tng cyclone trao i nhit, c thit b canxi ho trc khi nung. - Vi ngun nguyn liu di do : tr lng vi gn 150 triu tn, tr lng st hn 36 triu tn, cung cp cho nh my sn sut trong vng 100 nm. Cht lng tt, t tp cht, hm lng CaCO3 >92%, MgO < 3%, m bo cc yu cu cho sn xut xi mng. - vi c khai thc bng phng php ct tng, khoan v n mn khi ln. Xe vn ti chuyn v my p gia cng thnh dm c 25x25 v c chuyn vo kho nguyn liu bng h thng bng ti. Cng sut my p 1500 tn/h. Ngnh khai thc m c trang b cc loi my khoan, my xc, my i, xe vn ti loi ln v hin i ca Thy in, Nht Bn, nng lc phc v sn xut cho c 2 dy chuyn. - Kho nguyn liu dy chuyn 2 c sc cha : vi : 10600 m3x2 ng st : 4700 m3x2 ng Cc loi nguyn liu vi, st c ng nht s b ti kho ny. - My sy nghin lin hp chu trnh kn vi h thng thit b phn ly c hiu sut cao, h thng lc bi in, phi liu lun c iu chnh t yu cu v cht lng, mn v ng nht. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
32

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My nghin nguyn liu dy chuyn 2 c cng sut 300 tn/h. - My nghin than trc ng ca dy chuyn 2 cng sut 40 tn/h, cho php nghin than c m n 20%, tit kim 10% in nng. - L nung dy chuyn 1 vi h thng sy s b 4 tng cyclone trao i nhit. L quay c ng knh 5,5m, di 89m, h thng lm lnh kiu UNAX, cng sut 3100 tn/24h. Nhin liu nung bng than cm kt hp phun du MFO. - L nung dy chuyn 2 : + L quay ng knh 4,15m, di 71m, h thng lm lnh kiu ghi. + Nhin liu nung bng than cm nghin mn, c h thng SCANNER gim st nhit v l. - C hai dy chuyn 1 v 2 u c h thng lc bi tnh in, hm lng bi khi vo my lc 41g/m3, sau khi lc ch cn 225mg/m3 kh (dy chuyn 1) v 100mg/m3 kh (dy chuyn 2), m bo v sinh mi trng. - Phng iu khin trung c trang b thit b o, h thng mn hnh mu cng nghip v h thng vi tnh, h thng lin lc v tuyn, hu tuyn gim st v iu hnh cht ch cc thng s v hot ng ca thit b t khu u n khu cui. - Trung tm x l vi tnh vi h thng my tnh in t hin i lm nhim v lp chng trnh v x l cc

Sinh vin thc hin: Hong Minh Sng Lp KT2 K46

33

 n tt nghip

thng s k thut gip cho vic vn hnh thit b chnh xc, t nng sut cao. - My nghin xi mng hot ng theo chu trnh kn vi thit b phn ly hiu sut cao v h thng lc bi tnh in, sn phm lun m bo mn. My nghin xi mng dy chuyn 1 cng sut 176 tn/h. My nghin xi mng dy chuyn 2 cng sut 200 tn/h. - H thng sil cha xi mng bt gm 5 sil cao 42,5m, ng knh 16m, sc cha 39500 tn. - Tm my ng bao loi 12 vi, cng sut mi my 90 tn/h, m bo ng bao trng lng 50kg 1. Xi mng ng bao c chuyn v xut xung cc phng tin ng thu, ng b, ng st bng h thng bng ti. - Cng xut xi mng ng thu, x lan 300 tn vo nhn hng thun tin. - Xng sn xut v bao cng sut 40 triu chic/nm, thit b may bao ca Nht. - Phng kim tra cht lng sn phm (KCS) c trang b cc phng tin kim nghim v o lng hin i nht, qun l cht ch cht lng t khu nguyn liu, bn thnh phm clinke n xi mng xut xng. Nh vy sn phm lun n nh v cht lng, t cc tiu chun quc t. - T nm 1983 n nay, xi mng Hong Thch mang nhn hiu con s t gp phn xy dng nhiu Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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 n tt nghip

cng trnh trng im ca Nh nc nh cu Thng Long, thu in Ho Bnh, Bo tng H Ch Minh

Sinh vin thc hin: Hong Minh Sng Lp KT2 K46

35

 n tt nghip

Chng 2 : H thng l nung clinke dy chuyn HT II

1 - Khi qut v cng ngh: a. Cc qu trnh ho l v phn ng ho hc xy ra trong qu trnh to clinke xi mng pooclng :

Sinh vin thc hin: Hong Minh Sng Lp KT2 K46

36

 n tt nghip

Nhit Cc (0C) (1)< 100 (2)100 400

qu Cc phn ng ho hc

trnh ho l Sy, loi nc H2O(l) t do - Loi nc hp ph H2O(g)

Sinh vin thc hin: Hong Minh Sng Lp KT2 K46

37

 n tt nghip

(3)400 750

- Phn s thnh

hu 2(Al2O3.2SiO2) + hnh 4H2O

t st vi Al4(OH)8Si4O10

metacaolini t (4)600 900 - Phn hu Al2O3.2SiO2 Al2O3 + 2SiO2

metacaolini t thnh hn hp do - Phn s thnh v CA - Lin xt phn ng t

(5)600 1000

hu CaCO3 hnh CS

CaO + CO2 2(CaO.SiO-

vi v 3CaO+2SiO2+Al2O3
2

)+CaO.Al2O3

(6)800 1300

kt CaO.SiO2 + CaO

2CaO.SiO2

ca vi t do v CS, CA vi

2CaO + SiO2 2CaO.SiO2 CaO.Al2O3 + 2CaO 3CaO.Al2O3 Fe2O3

s CaO.Al2O3+3CaO+

hnh thnh 4CaO.Al2O3.Fe2O3 C2S, C3A v (7)12501450 C4AF Lin kt 2CaO.SiO2 + CaO 3CaO.SiO2 vi

Sinh vin thc hin: Hong Minh Sng Lp KT2 K46

38

 n tt nghip

b. Yu cu k thut i vi clinke xi mng pooclng sn xut ti Cng ty xi mng Hong Thch : (TC 03-2003) Cc ch tiu CaO t do, %, max CaO, % SiO2, % Al2O3, % Fe2O3, % MgO, %, max H s bo ho vi LSF M un silc SIM M un nhm ALM Gi tr 1,5 58 67 18 26 38 25 5 88 100 2 2,6 0,7 2

H thng l nung dy chuyn II: L II l h thng l quay phng php kh nhng s dng thp trao i nhit 1 nhnh 5 tng cyclone s dng calciner tin nung v gin ghi lm lnh clinke COOLAX COOLER. l 2 im khc bit c bn ca h thng l II so vi l I. Bt phi liu c tho t y sil ng nht tinh CF xung kt cn W2A01, nh vt ti W2A06 a ti chn 1 trong 2 gu nng W2A20, W2B20 (1 chic d phng) ri a ln mng kh ng W2A21, qua van tip liu cnh kh W2A26 xung van i trng W2A27 vo on ng cong gia cyclone tng 4 (W2A52) v cyclone tng 5 (W2A51). Ti y bt liu gp dng kh nng i t ng ng ca W2A52 thi ln cun vo cyclone W2A51 theo phng tip tuyn vi thnh cyclone. Bt liu c lng xung y ri qua van i trng chy xung on ng cong gia cyclone tng 3 (W2A53) v cyclone tng 4. Qu trnh trao i nhit v phn ly tng t nh vy tip tc din ra cc 39 Sinh vin thc hin: Hong Minh Sng Lp KT2 K46

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tng cyclone tip theo. Sau khi c lng ti cyclone W2A54, bt liu qua van chia liu W2A71, khong 40% bt liu a xung bung khi a ln cyclone W2A55, khong 60% s qua van chia liu W2A73 cp vo 2 tng ca calciner W2A56 (t l chia dao ng : tng trn/tng di 30/70) thc hin qu trnh canxi ho. Kh cung cp cho qu trnh chy trong calciner l gi nng c thu hi t gin ghi lm lnh clinke COOLAX COOLER qua ng gi 3. Bt phi liu t calciner c ht sang W2A55 qua van i trng ri vo l quay W2W01. Kh nng ln bt liu mn cha phn ly ht trong W2A51 i ra qua ng ng di sc ht ca qut ht u l J2J15 vo thp lm lnh J2K11 (mt phn sang my nghin nguyn liu), vo lc bi in u l J2P21 lng nt bt liu. Kh thi sau lc bi in c qut J2P27 ht thi ra ngoi tri qua ng khi u l. Sau khi ra khi l quay, clinke xung gin ghi W2K01 v c lm lnh nhanh v lm ngui trc khi vo my ba W2M01 p ti kch thc yu cu ( 25 mm). Gu xin W2K08, gu nng W2J12, xch co W2J13 c nhim v vn chuyn clinke sau khi ra khi my ba vo sil cha clinke. L II s dng thp trao i nhit 5 tng c calciner nn liu trc khi a vo l quay t t0 885 0C, tc l cc qu trnh ho l t (1) n (6) c thc hin (hon ton hoc phn ln) thp trao i nhit. Bi vy, trong l quay ch yu thc hin cc qu trnh (5), (6), (7). l nguyn nhn chnh lm cho l quay W2W02 c kch thc nh gn hn l quay W1W01. 2 - Cc thit b chnh trong phn xng l nung : Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Xng l nung gm cc cng on : - Cng on ht x l kh thi - Cng on cp liu - Cng on l - Cng on nghin than v ni hi Vi rt nhiu thit b, trong c cc thit b c trng quan trng ca phn xng nh : h thng thp sy s b 5 tng, calciner, l quay, thit b lm lnh kiu ghi, vi t, thp lm lnh 2.1 - Cyclone trao i nhit :

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H thng cyclone (lp t thnh thp) c s dng sy tch m v thc hin mt s qu trnh ho l, ho hc i vi bt phi liu trc khi cp vo l quay nhm gim thiu cc b phn trong h thng l, t gim tiu hao nng lng (in nng, nhit nng). a. Cu to: L kiu cyclone st thp, dy chuyn II s dng loi thit k mi. b. Nguyn l hot ng: Trong thp trao i nhit, kh nng i v bt phi liu c vn chuyn ngc chiu nhau. Kh nng i t di ln nh sc ht ca qut ht u l. Bt phi liu i t trn xung di tc Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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dng ca trng lc. Qu trnh trao i nhit gia kh nng v bt phi liu bt u khi chng gp nhau ng ng ca cyclone tng di (ngay sau hp tn liu). ng ng t tng cyclone di i vo cyclone tng trn theo phng tip tuyn. Bt phi liu v kh nng s chuyn ng xoy theo thnh cyclone. Lc ly tm tch cc ht liu ra v chng va chm vi thnh cyclone khin cc ht b mt dn ng nng cho ti khi trng lng cc ht thng c sc ht ca qut ht u l th ht bt liu s ri xung y hnh nn ca cyclone. Kh nng v mt phn bt liu cha phn ly ht s tip tc chuyn ng xoy ln v thot qua ng lng nh cyclone, theo ng ng ln tng cyclone tip theo (hoc ti thp lm lnh). ng lng ngn khng cho cc ht bi thot qua nh cyclone, tng hiu sut phn ly. Bi vy, cyclone thc cht va l thit b trao i nhit, va l thit b phn ly rn kh. c. Mt s c tnh k thut v yu cu cng ngh ca thp trao i nhit 5 tng dy chuyn II: 1- Cyclone W2A51 : ng knh : D = 6900 mm Chiu cao phn tr : 14267 mm Cng sut phn ly : 93% 2 - Cyclone W2A52 : ng knh : D = 6900 mm Chiu cao phn tr : 9305 mm Cng sut phn ly : 88% 3 - Cyclone W2A53 : Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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ng knh : D = 7200 mm Chiu cao phn tr : 9725 mm Cng sut phn ly : 85% 4 - Cyclone W2A54 : ng knh : D = 7200 mm Chiu cao phn tr : 9725 mm Cng sut phn ly : 82% 5 - Cyclone W2A55 : ng knh : D = 7200 mm Chiu cao phn tr : 10352 mm Cng sut phn ly : 78%

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V tr

nh mc

Max I (H1) (0C) 440 825 825 825 825 825 825 925 900 (mbar)

Max II (H2) (0C) 500 850 850 850 850 850 850 910 775

Min I (L1) (0C) 100

Min II (L2) (0C)

(MV) im o nhit (0C) W2A50T1 W2A52T1 W2A52T2 W2A53T1 W2A53T2 W2A54T1 W2A54T2 W2A55T1 W2A55T2 im o p sut W2A50P1 W2A52P2 W2A53P2 W2A54P2 W2A55P1 W2A55P2

561 555 686 668 789 772 886 866 (mbar) 61 40 38 28 19 22

(mbar)

(mbar )

10 10 10 10

Bt phi liu trc khi vo thp sy s b phi t ch tiu : - m : < 1% - st sng R0009 : 15% 2.2 - Calciner (Bung phn hu trc) W2A56: Ch yu thc hin qu trnh canxi ho bn ngoi l quay, gim ti nhit ca zone nung trong l quay (khong 60% nhin liu t trong calciner). Qu trnh canxi ho trong calciner xy ra rt nhanh. Do vi kch thc l nht nh

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c th tng nng sut l quay ln gp 2 ln so vi l quay phng php kh c thp trao i nhit kiu treo. a.Cu to : Loi SLC S (Sperate line calciner - special) Calciner c cu to gm 2 tng hnh tr tht gia : - ng knh phn tr : D = 6000 mm - Chiu cao tng trn : 12000 mm - Chiu cao tng di : 6000 mm Calciner c 3 u vo v 1 u ra: * u vo : - Bt phi liu: Bt phi liu t cyclone W2A54 qua h thng van i trng, van chia liu, W2A71, W2A73 vo calciner qua b phn tn liu. Vic chia liu vo 2 tng Calciner do W2A73 thc hin. T l chia l thuyt l : tng trn/tng di 30/70. Song thc t, t l ny lun dao ng ph thuc vo nhit W2A56T8. - Nhin liu: Nhin liu s dng cho Calciner l than cm 3b. Bn cnh cn s dng du MFO sy v gas mi. Bi vy Calciner dng 4 vi t du, 2 vi than v 1 m t gas b tr y tng di. - Gi nng: Gi s dng cho qu trnh sy v t trong Calciner l gi nng thu hi t gin ghi lm lnh clinke COOLAX COOLER (cn gi l gi 3). * u ra:

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L hn hp phi liu c canxi ho ( 90 95%) v gi nng. b.Nguyn l lm vic: Gi 3 c iu chnh lu lng bng van W2A76 v c gia nhit nh trm t du W2V31 (khi nhit gi 3 thp). Dng vi gas mi trong giai on bt u sy Calciner. Khi nhit gi 3 t nhit bt chy ca du MFO th bt u khi ng cc vi t du. Than ch c cp vo khi Calciner ang t du c ch chy n nh. Qu trnh canxi ho c thc hin nh nhit ca qu trnh t than. Phi liu c cp vo qua 2 ca tn liu b tr gn ranh gii gia phn tr v phn cn y ca 2 tng. Di sc ht ca qut ht u l phi liu c cun ln nh Calciner cng vi gi nng. c.Cc thng s vn hnh ca Calciner : V tr Tn gi c trng caKhong vn hnh Max I Max II (MV) 0 C 1065 1106 994 1022 990 1054 mbar 5 (H1) 0 C 1150 1100 1100 1190 1000 1230 (H2) 0 C 1200 1150 1150 1195 1100 1250

thng s im o nhit d W2A56T1 W2A56T2 W2A56T3 W2A56T6 W2A56T7 W2A56T8 im o p sut W2A56P2

Nhit nguyn liu vo Calciner 8000C Nhit gi nng: 850 - 9000C Nhit lm vic ca Calciner: 10000C Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Thi gian lu liu trong Calciner theo thit k khong 3 giy nhm t chy ht nhin liu. C 1 trm t du W2V21 phc v cho vic sy Calciner. 2.3 - L quay:

L quay l thit b trung tm ca h thng l. N lm nhim v chuyn ho bt phi liu mn thnh clinke xi mng nh qu trnh t trong l. L quay c hiu l mt ng gin n nhit bng thp chu nhit, bn trong lt gch chu la. Trong l s dng nhiu loi gch chu la khc nhau v b tng chu la cc b cn u vo v u ra l. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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L c t nghing trn cc b vi cc con ln ( s b ph thuc kch thc v kt cu l) v c dn ng bi h thng vnh rng l lp c nh trn v l v cc ng c l. Cc vnh bng a lp lng trn v l nh cc guc l, c nhim v thn l v gip qu trnh quay ca l d dng hn. l lun v tr lm vic n nh, h thng con ln y thu lc vi bm du thu lc c lp t ti cc b gn u vo ca l. Qu trnh cung cp nhin liu v iu chnh qu trnh t trong l quay c thc hin nh mt vi t chnh (vi t a knh). Gii thiu l nung clinke dy chuyn II (l quay W2W01) : - Loi : FLS - SLC 4,15*71 + Coolax 1266 - Di :71 m - ng knh : 4,15 m - nghing ca l : 4% - Tc quay ca l khi chy ng c chnh : 0,1 3,25 v/ph (ng c in 1 chiu) - Tc quay ca l khi chy ng c ph : 0,1 v/ph (ng c in xoay chiu) - Nng sut thit k : 3300 tn/ngy - T l t nhin liu trong l : 40 45% - Nhin liu t chnh : 100% than cm 3b - Trm t du W2V11 phc v cho vic sy l L c lp trn 3 b . Con ln y thu lc (con ln ch T) c lp b s 3 ca l. L c dn ng bi ng c

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chnh W2W03 qua hp gim tc W2W02 truyn chuyn ng quay cho vnh rng l W2W31 nh khp ni mng. Cc thng s k thut ca W2W03 : N = 50 1000 v/ph P = 22,5 450 KW Cc thng s k thut ca W2W02 : P = 450 KW N = 31,28 1000 v/ph Nu phi quay chm l th ng c chnh W2W03 dng v chy ng c ph W2W06. 2.4 - Thit b lm lnh clinke : H thng l dy chuyn II s dng thit b lm lnh kiu ghi (COOLAX COOLER)

a. Mc tiu ca lm lnh kiu ghi : - Lm lnh nhanh v lm mt clinke trc khi a ti cc thit b vn chuyn. - Thu hi nhit nng a ti cc v tr cn thit trong h thng l (Calciner, nghin than,) t hiu qu kinh t Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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cao nht. y l u th ca h thng l s dng thit b lm lnh kiu ghi so vi thit b lm lnh kiu hnh tinh. b. Cu to v nguyn tc hot ng : + Loi : Coolax 1266 HY 2D + C 2 modul : - Gin ghi CFG (gin ghi I) : gm 3 khoang di gm gin ghi v c 2 qut lm kn ring bit vi 6 qut lm mt clinke. - RFT (gin ghi II) : gm 4 khoang di gm gin ghi, qut lm mt clinke ng thi l qut lm kn khoang. C 2 modul ny cng c kt cu bi h thng cc hng ghi ng xen k cc hng ghi tnh. Cc hng ghi ng (gm cc tm ghi lp trn cc v lp trn cc thanh dm ngang) lp trn 2 thanh dm ng c kh nng dch chuyn dc theo chiu di ghi nh cc piston xilanh thu lc b tr u v 2 bn ghi. Cc hng ghi tnh (gm cc tm ghi lp trn cc v lp trn cc thanh dm ngang) lp trn 2 thanh dm c nh dc theo chiu di ghi. Cc thanh dm, tm , tm ghi u c kt cu rng, khi lp rp thnh mt h thng th c tc dng nh mt ng ng dn kh t qut ln mt tm ghi lm mt clinke. + Kch thc : - Chiu rng danh nh : 2,4x3,6 m - Chiu di danh nh : 21,8 m - Din tch hu ch ghi lm ngui : 71,7 m2 - u ra ca l v b phn lm kn c lm mt bng kh t qut trung p. Cc vi phun c b tr 3/4 ng trn pha di.

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+ H thng cung cp kh lm mt gm 11 qut (W1K10, W1K11, W1K12, W1K13, W1K14, W1K15, W1K17, W1K18, W1K19, W1K20) + 2 qut lm kn cho gin ghi CFG : W1K09, W1K16. + My p clinke FK 90x300. + H thng phun nc lm mt kh d W1K46 Clinke t l quay ri xung u gin ghi CFG gp dng kh p lc cao do cc qut W2K10, W2K11 cung cp thi ln qua cc tm ghi v c lm lnh t ngt. Sau clinke c vn chuyn dn ti cc khoang tip theo ca gin ghi CFG v gin ghi RFT ti my p ba W2M01 nh s dch chuyn ca cc hng ghi ng trn b mt cc hng ghi tnh. Trong sut qu trnh vn chuyn , clinke tip tc c lm mt nh h thng cc qut lm mt ghi. Cui gin ghi RFT c mt ghi sng phn loi clinke, cc ht clinke c kch thc t yu cu ( < 25 mm) s lt qua ghi sng xung gu xin W2K08. Lng clinke cn li s qua my p ba W2M01 p ti kch thc yu cu. Sau khi ra khi ghi, nhit clinke khong 150 1800C. Di sc ht ca qut ht u l J2J15, khng kh sau khi lm lnh clinke, mt phn ln tham gia vo qu trnh t nhin liu trong l, mt phn c thu hi qua ng gi 3 ti lm gi t trong Calciner (gi 3). Phn cn li (ch yu gin ghi RFT) s c ht sang lc bi tnh in W2P21 nh qut W2P27 lng bi ri a gi nng sch ti nghin than K2 sy than trong my nghin v sang l I lm gi 1 cho l.

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H thng phun nc lm ngui kh d W2K46 gm 2 gin vi phun b tr 2 bn thnh ca bung ghi c nhim v iu chnh nhit kh trc khi vo lc bi in W2P21. 2.5 - Vi phun : L II s dng vi phun Centrax.

y l loi vi phun a knh bao gm vi t gas, vi phun du, knh than, knh kh. Theo thit k, vi t 100% than. Vi phun c treo trn 1 b gi c kt hp mang c ng ng gi 1 ni vi qut thi W2V91. Vi phun c treo trn dm dc sn l qua ng c ca gi 1 vo tip nhn gi 1 t qut W2V91. ng vi phun c lp bao quanh ng . Gia thn ng v ng vi phun c 1 khe h cch u sut dc chiu di thn ng. ng vi phun c ni vi ca gi 1. ng than ngoi c lp bn trong ng t ln cc cnh dn hng. Vnh phun ngoi c hn ln ng vi phun v ng than ngoi. ng vi phun v phn ngoi cng ca vnh phun ngoi c ph 1 lp b tng chu la bo v vi phun trong iu kin nhit cao. Ca vo than c ph 1 lp chu mn c bit. Ca ny ni vi ng than 53 Sinh vin thc hin: Hong Minh Sng Lp KT2 K46

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ngoi. Mt khc, ca than vo cn c ni vi ng bng ng mm. ng bo v trung tm c lp trong ng than trong. Bn trong ng bo v c ng bo v vi phun du tm v ng bo v vi t gas bn cnh. Vi phun du v vi t gas c th ko ra khi ng bo v v sinh v bo dng. ng bo v trung tm v ng than trong c hn ni vi nhau bng vnh phun trong. 2 vnh phun c 2 vng l b tr u xung quanh cp gi 1 v than vo l. Nh vy cc ng bng thp chu nhit trong vi phun Centrax phi hp vi nhau to thnh : - ng gi 1 ngoi : do ng vi phun ghp vi ng . - ng gi hi v : do ng kt hp vi ng than ngoi. - ng than : do ng than ngoi v ng than trong kt hp to thnh. - ng gi 1 trong : do ng than trong v ng bo v trung tm to thnh. 2.6 - My nghin than : a. My nghin ATOX KM 27.5 : * Gii thiu : - L my nghin ng chu trnh kn sy nghin lin hp. - Kiu my nghin ATOX. - Loi KM 27.5. - Gim tc loi TDVLA 1270. - Phn ly kh loi RAKM 27. - Cc b phn nghin gm c 3 roller v bn nghin. - p lc nghin (Pw) = 90 150 bar. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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- mn sn phm < 6% trn sng 90 m. - m : < 1%. - Nng sut : 40 t/h. - Tc nhn sy : + Kh thi ghi lm ngui clinke + L t ph - Nhit kh nng vo my nghin ~ 3000C. - Nhit sau my nghin 80 0C m 1% H2O : + Tmax1 = 80 + 50C + Tmax2 = 80 + 10C * Cu to :

B phn nghin gm c 1 bn nghin c dn ng bi 1 ng c (K2M03) v 3 con ln nghin vi h thng thu lc Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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(gm 1 bm du, 3 xi lanh thu lc, mi xi lanh c s h tr ca 2 bnh tch nng). Trn bn nghin c 1 ng nghin chy vng trn. ng nghin c cc tm lt chu mn nhit lm bng hp kim Cr Ni. Vnh chn than c lp vng theo mp bn nghin, c chc nng dn than vo ng nghin to ra 1 lp m nghin. Thanh gt np ti mt di ca bn nghin c nhim v gom than ri qua ming vnh chn xung tm di ca v my nghin ra ca . than c a tr li bung nghin nh qut gi K2M09. Ba con ln nghin c lp c nh trong khoang my nghin tng quan vi v my nghin nhng quay quanh trc c gi cht bi gng trung tm. Con ln nghin quay quanh trc bng con ln bi trn m. Trc c lp cc bc lt cho 4 vng lm kn trc. Chc nng ca chng l ngn cn 1 phn m np gi trong con ln v ngn cn bi than xm nhp vo con ln, lm kn trc trn c 21 mt con ln. Trong con ln c bo v 1 ln na bi h thng kh lm kn. Kh lm kn c cung cp bi qut K2M06. T bn ngoi v my nghin, kh lm kn i vo gng trung tm ri i theo cc mng ti trc ca 3 con ln. Cc con ln nghin c bc bi cc tm chu mn. Cc tm ny c c nh bi cc b gi kp v cc vt hm. * Nguyn l hot ng : Than th t kt than th K2L01, nh lng nh cn simat K2A01 v cp vo tm my nghin K2M01 bng vt ti i K2A02. ng c K2M03 quay, mmen chuyn ng c truyn ti bn nghin thng qua hp gim tc K2M02 v lm bn Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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nghin quay theo. Khi bn nghin quay, lc ly tm xut hin v hng dng than th i vo ng nghin. Than c nghin mn nh lc tr st gia cc con ln vi mt bn nghin. Vic nng h cc con ln nghin cng nh vic to ra p lc nghin l nh h thng thu lc. Trong h thng thu lc, bm K2M07M1 c nhim v cung cp du cho cc xi lanh v cc bnh tch nng nhm duy tr p lc nghin. Qut K2M06 c chc nng lm kn cc con ln nghin. to c lp m nghin thch hp (d = 29 30 mm), bm nc K2K01 vi 3 ng phun nc trc tip ln lp than mt bn nghin. Lp m nghin ny c tc dng gip n nh p lc nghin cng nh trnh rung cho my nghin, p sut m trong h thng my nghin c to ra bi qut ht K2P22, nh gi nng thu hi t gin ghi lm lnh c ho trn vi kh hi lu sau lc bi in i vo my nghin qua vng phun gi nng thc hin ng thi 2 nhim v : sy kh v cun than mn ln thit b phn ly K2S01. Phn than mn t yu cu tip tc theo dng kh nng vn chuyn qua ca ra nh my nghin. Cc ht th b cn li v tr li bn nghin nghin tip ti khi t kch thc yu cu. * Phn ly kh loi RAKM 27 : Phn ly dng trong my nghin ATOX l thit b phn ly kh ng dng phn ly cc ht than mn t my nghin a ln bng lung kh nng. Cu trc ca phn ly gm : 1 rto , cnh dn hng , v phn ly , chp y v van cn. V phn ly bao gm 2 phn cn v c lp trc tip ln v my nghin bng bu lng. Ca x ca kh v bi mn Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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thot ra khi thit b c b tr trn nh my nghin. Rto c cc cnh thng ng lm bng thp chu mi mn. Rto ny c lp trn 1 trc thng ng. Trc rto nhn mmen chuyn ng t ng c thng qua hp gim tc. Cnh dn hng l nhng tm thp, 1 u c bt cht vi v thit b, u di gn vi phu hnh cn. Van cn l loi van i trng, chc nng ca n l cho liu ri xung m kh t khoang nghin khng th i ln c. Hin nay, thay van cn bng 1 ng dn trc tip than th chy xung bn nghin. b. Yu cu k thut ca than lm nhin liu ti Cng ty xi mng Hong Thch : My nghin than ATOX KM 27.5 Than nhp v l than cm 3 tho mn TCVN 1789 - 1999

Cc ch tiu Gi tr tro, %, max 1,5 Cht bc, % 8 Nhit lng, Kcal /kg than mn 7050 m, %, max 13,5 Kch thc 15 mm Lng qu c t 15 25 mm khng qu 5%

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Chng 3 : cc h thng iu khin l nung clinke

1. Tng quan Trong cc chng trc chng ta bit qua v cng ngh ca qu trnh sn xut xi mng, cu to ca h thng l nung v qu trnh bin i ho hc ca liu khi nung hnh thnh clinke. Vic tnh ton cc ch tiu thng s chun c cc nh cng ngh thc hin v n c gi khng i trong qu trnh hot ng ca l. Yu cu t ra l phi iu khin ti u ho h thng l. Vic iu khin ti u ho h thng l s lm cho cht lng clinke tt hn, h thng lm

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vic vi chnh xc cao hn, tng cng sut, tit kim nhin liu nhng vn m bo cht lng v sn lng clinke. thc hin bi ton ti u, nh my xi mng Hong Thch dng h thng chuyn gia iu khin h thng l. H thng chuyn gia iu khin ch nhit iu khin ch kh ng iu khin cp liu

Hnh 3.1. H thng iu khin chuyn gia HT II H thng chuyn gia iu khin l t ng l h thng trn c s hiu bit cho mt nh my c th, c h thng gim st v iu khin hot ng ca l v lm ngui mc cao. H thng chuyn gia iu khin l tr gip ngi vn Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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iu khin truyn ng quay

Cng ngh sn xut clinke

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hnh l trong vic to ra cc iu kin vn hnh tt nht cho vic vn hnh l n nh, cht lng clinke thch hp, sn lng ti a v tiu th nhin liu t. c im ca h thng iu khin chuyn gia l n iu chnh im t ch khng phi l duy tr im t ca cc chu trnh n. V d h thng c th tng im t cho nhit ca qu trnh canxi ha nu mmen l b gim. H thng chuyn gia c s dng l h thng chuyn gia Fuzzy. Vi h thng ny hot ng ca l c thng nht vi cc hot ng iu khin thng xuyn v ng tin cy hn so vi ngi vn hnh. H thng iu khin ny s tng ng k s n nh ca l v iu khin l trong khong t nht 80% thi gian vn hnh. S n nh ca l s m bo gim nhit lng tiu th khong 3% - 5%, nng tui th ca gch chu la ln khong 30% - 50%, sn xut ra clinke ng nht hn c cng xi mng cao hn v gim lng tiu th in nng trong my nghin xi mng, tng cc h s hot ng v nng sut ca l. Chin lc iu khin cho l gm 4 nhm sau: - iu khin zn nung. - iu khin qu trnh chy. - iu khin b lm ngui. - iu khin khi ng l. Mi nhm u c cc mc tiu th t u tin ring trnh mu thun. Cc mc tiu in hnh trong zn nung theo trt t u tin l: - Kim sot s c: trnh cc iu kin l nng/lnh. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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- Vn hnh n nh: n nh vn hnh l. - Cht lng clinke: p ng cc yu cu v cht lng. - Sn xut: ti a ho sn lng. Cc mc tiu c th t u tin cao hn c quan tm trc nht, v nu cc mc tiu ny khng c p ng th cc mc tiu c th t u tin thp hn tm thi khng c nhc n. V d nu zn nung bi lnh th cp liu c th b gim thm ch iu ny c mu thun vi cc yu cu v ti a ho sn lng. H thng chuyn gia l dng cc kt qu o qu trnh cho cc hot ng iu khin. S t nhng kt qu tt nht nu c th gim thiu nhng trc trc, nh cp liu l khng u hoc nhng thay i trong nhit tr ca than. Tuy nhin h thng chuyn gia l hot ng tt trong phm vi thay i rng v m bo cc hnh ng tc thi t c hot ng n nh l. iu khin c thp trao i nhit v b lm ngui, h thng chuyn gia l phi cn cc kt qu o qu trnh nh lit k di y, nu t ngt mt mt tn hiu khng hot ng, h thng chuyn gia vn c th tip tc hot ng nhng hiu qu b gim i. %O2 v %CO ti u vo ca l. %O2 v %CO trong kh thi thp trao i nhit. Dng ng c l v/hoc %NOx ti u vo ca l v/hoc ho k trong zn nung. Nhit kh thi thp trao i nhit. Nhit bung phn hu. Vi t o v/hoc dung trng lt. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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p sut di ghi b lm ngui. H thng chuyn gia l s iu khin: Cp liu l. Than cho vo l v bung phn hu. V tr ca van iu tit gi 3. Tc qut ID ca l hoc v tr ca van iu tit. Tc l. Tc ghi ca b lm ngui. Lu lng kh lm ngui t cc qut b lm ngui. Cc kt qu o ca qu trnh cng ngh phi thng xuyn c kim tra v duy tr h thng hot ng tt. Ngi vn hnh l phi nh k nh gi tnh hnh bng cch s dng cc thng s iu khin quen bit khng nhng trong thc ti m cn phi xem xt tnh hnh s tin trin ra sao trong khong thi gian sau ri s quyt nh phi lm g nu cn. Nu l khng cn bng hoc c du hiu trc trc, ngi vn hnh c th can thip theo mt trong hai chin lc khc nhau: C th thay i i cht tc l v nh vo vic ng b l, mc cp liu s t ng thay i theo. V ta phi nguyn mc nhin liu v ngun gi. C th gi nguyn tc l v cp liu nhng iu chnh vic t trong l v lung gi cho thch hp.

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2. H thng iu khin lu lng liu cp cho l 2.1. Gii thiu h thng cp liu l nung LOW (mt trng lng) FLS: Mc ch ca h thng cp liu l nung l m bo lng liu thch hp c cp vo l nung, ng b vi tc quay ca l v m bo cho l hot ng tt. Nh vy ta thy h thng iu khin cp liu l nung khng tch ri m l mt hot ng quan trng trong cng on iu khin l. Vic la chn h thng cp liu l nung ph thuc vo loi l nung v s sil bt liu cng vi thit b vn chuyn gia b phn cp liu vo l nung. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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H thng cp liu l nung FLS LOW ch yu c dng trong h thng cp liu l nung c lp di sil CF. Kt cn c lp Nivopilot, mt b phn an ton ngn khng cho kt qu y v c thit b thng gi ho lng bt liu trong b. Ba b cm bin ti trng o trng lng ca kt, p dng ba mc ti trng. Mc ti a s ngng qu trnh rt ra t sil CF v mc ti thiu s rt liu t sil CF, mc thp hn mc ti thiu s bo ng. Mi ca ra t b c lp mt ca iu khin dng chy, hot ng bng kh bt hay tt v mt ca iu khin dng chy chy bng ng c iu chnh mc liu rt ra t kt cn. S mt ti trng c o hng gi vi s iu chnh tng ng cc l m ca ca iu khin dng chy hot ng nh ng c. V mc rt ra tht ch c o trong thi k m khng cung cp nguyn liu vo kt cn, mc trong b c iu chnh theo chu k. Mi chu k gm mt giai on vo khi nguyn liu c cp vo trong kt v ng thi c rt ra trc qu trnh rt nguyn liu ra m trong qu trnh ny ch c hin tng rt nguyn liu ra. Trong qu trnh rt ra, c 2s li ghi trng lng ca kt. Cc s ghi c ny c chuyn thnh mc dng chy cp liu cho l nung, mc ny c so snh vi mc t ra cho yu cu ca cp liu l nung v iu chnh l m ca iu chnh dng chy nu c sai lch. Khi vic vo kt cp liu l nung t n mt mc thp c xc nh t trc, th chng trnh rt ra t y sil t ng c phc hi v qu trnh nguyn liu vo b li c phc hi. 2.2. H thng iu khin cp liu l nung HT II: Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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2.2.1. Gii thiu: H thng iu khin cp liu l nung LOW v h thng iu khin sil CF Hong Thch II c trnh by trong hnh 3.7, bao gm cc phn sau: Control cabinet. Thit b cho phu cn. Van t trng iu chnh gi cho van lt. Cng tc khng tip xc cm ng iu chnh v tr ca van lt. B o p sut cho qut gi v my nn kh. Nivopilot trn bt liu trong b v phu cn. Van lt ca phu cn. Ca tho cho cp liu l nung. Van iu chnh cho cp liu l. H thng iu khin sil CF c th t ng chy lin ng vi s ng m ca van lt y sil, da trn mc liu phu cn. Trong ch t ng, nguyn l ng nht ca CF sil c tho mn, nu hot ng ch bng tay th van lt c m. H thng iu khin cp liu l LOW c th iu khin t ng nh mc cp liu l, da trn im t nh mc. Trng lng vt liu v v tr ca ca tho c iu khin vi s thc hin tnh ton cc tham s m LOW s t ng iu chnh. iu c th quyt nh gc m van trong ch bng tay. B iu khin l mt MasterPiece iu khin gim st th t rt v nh mc cp. 2.2.2. H thng sil CF: Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Nguyn l ng nht: vic ng nht t c trong sil CF bng cch rt liu ti cc ca ra y sil, m c tin hnh nhiu mc dng chy khc nhau v trn bt liu t ca ra ring r trong mt b trn l tng nh. y ca sil c chia thnh 7 khu vc su cnh ging nhau, gia mi khu vc c mt l m b phn tho y bng mt hnh nn thot p sut. Mi khu vc li c chia thnh 6 phn hnh tam gic, nh vy y ca sil gm 42 phn, tt c u c lp nhng hp thng gi xp. C th thng gi ng thi c ba phn mt cch c lp nh kh t 3 my thi quay. Cc l m b phn tho c lp cc van np. T cc van ny nguyn liu c chuyn bng kh trt n b trn gia bn di sil. Bng thng gi mnh bt liu c ho lng trong b trn. Lng liu trong b trn tng ng vi 12 pht tiu th ca cp liu l nung. B trn c t trn cc b cm bin ti. Bo hiu v trng lng t cc hc bnh ny c s dng cho hai mc ch: Khi ng v ngng ton b qu trnh rt ra t y sil gi mc nguyn liu trong b cc gii hn cho php. Trong cc giai on m ton b qu trnh rt ra t y sil c ngng li, s mt trng lng ca b trn c tnh ton v s dng iu khin cc van quay di b trn, iu chnh cp liu l nung. Do vy khng cn c h thng cn cp liu l nung b sung. Hot ng ca sil CF c cc cm PLC iu khin c lp vo mt h thng thit b vi x l. Thit b vi x ny Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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iu khin trnh t rt ra t 7 ca tho y sil bng cch iu khin vic ng v m cc van np v qu trnh thng gi ca cc phn. Khi b cp liu l nung t n mc ti a th chng trnh c ngt. Khi mc trong b tt xung th chng trnh li c tip tc. Mc tho liu ti u t 7 ca tho c tnh ton da trn c s: Mc trung bnh ca liu trong sil. Tng nh mc cp liu n l. Chu k thi gian cho mc dao ng tri nht u vo sil.

2.2.3. H thng cp liu cho l nung LOW: a. Nguyn l hot ng Bt liu rt ra t sil CF theo chng trnh, sau c cung cp cho kt cn. nh mc dng cp ca kt cn c iu chnh vt nh mc dng tho ca kt cn v n s b ngt nu liu trong kt t n mt mc cao nh trc. Khi liu trong kt n mt mc thp nh trc, vic tho t sil li hi phc. Liu trong kt cn lin tc c tho ra, chy qua thit b ng m bng kh ng v c dn bi ca iu khin dng chy hnh tr bng c. Thit b ng m kh ng c dng chc chn rng khng c liu khi cp liu l dng. Ca iu khin dng chy bng c kh c dng

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iu chnh li cp liu cho l, khi khng cp liu, ca ny s b ng xung an ton. Nguyn l chnh iu chnh liu cp cho l da vo vic o s khc nhau ca tn hiu trng lng kt cn theo thi gian. S khc nhau ny phn nh dng chy, c dng b iu khin mt trng lng LOW (Loss Of Weight) iu chnh v tr ca ca tho. Nguyn l ny c dng trong lc liu rng nhng khng th dng lc liu y, khi lng liu cp vo phu cn khng th nhn bit c. Thay vo cng thc ton hc c dng, n a ra quan h gia lu lng, v tr m van, trng lng o c phu cn:
F= Z X 1 + X 2 .Q + X 3 .Q 2

Trong :

F: lu lng (T/h). Z: v tr m van (%). Q: trng lng phu cn (T). X1, X2, X3: cc bin h thng.

Trong cng thc ta thy lu lng t l trc tip vi v tr m van v t l nghch vi hm ca trng lng phu cn. Cc bin h thng ph thuc vo hnh dng ca ca iu khin dng chy, s thng kh ca phu v tnh cht ca dng liu. c bin h thng chnh xc, chng phi c cp nht sau mi chu k tho.

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Trng lng kt cn

V tr m van time Hnh 3.8. Nguyn l iu khin h thng cp liu cp liu LOW b. Nguyn l iu khin: Nguyn l iu khin h thng cn LOW: iu khin lu lng, cc bin h thng phi o c. Cc ton t chn Setpoint lu lng Fsp, trng lng ca phu cn Q (c o bi 3 cm bin ti), o v tr van Zm v gi tr tc ng c. Hai tn hiu s c dng khi ng v dng cp liu Feed request v Return signal. thc hin c iu ny n c truyn thng vi H1 PLC. * Ch t ng (Hnh 3.9): bt u cp liu, n ch tn hiu Feed request t H1 PLC v s gi tn hiu Return signal. Tn hiu setpoint lu lng v bin vo, s c chp nhn khi tn hiu Feed request nhn c. Setpoint lu lng khong 30T/h. B iu khin LOW tip tc hot ng v gi tn hiu Return signal. Hm dc:

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S dng phng php ny, vn sai lch nh ca trng lng vo c gii quyt. Hm dc c th ch c s dng trong chu k liu rng, bi v lng cp cho phu cn trong chu k y khng th xc nh. Vic ny c thc hin bng tip im c tn Shifted during emptying period. S gim dn trng lng c bt u ngay khi bc vo chu k rng. N bt u vi trng lng khi ng (Qstart) v gim xung theo thi gian theo hng bm lu lng t. Bng chc nng ny trng lng t c tnh (Qsp), n c tr i trng lng tc thi ca phu cn, sai lch c dng iu khin ca tho. cp liu tt, sai lch trng lng phi nh mc cho php. iu ny c iu chnh bng b khuch i KP1, n c th cho gi tr ln. (Theo kinh nghim KP1 gi tr khong 50). Tnh v tr van: Hm dc s a ra lu lng ng cho h thng trong chu k rng, trong chu k y hm ny phi c ngt. V vy trong chu k y, cng thc ton phi c dng tnh v tr van da vo lu lng t Fsp v trng lng phu cn.
Z sp = F sp .( X 1 + X 2 .Q + X 3 .Q 2 )[%]

Vi gi tr lu lng t c nh, v tr van Zsp s l hm bc 2 ca trng lng phu cn. Gi tr v tr van ny c s dng iu khin trong c hai chu k. Trong chu k rng, Zsp s c iu chnh da theo sai lch ca trng lng. V tr t van mi s c tr i gi tr in p o v tr (Zm) m n gy ra sai lch lu lng (Zfault). Khu khuch i KP2 c dng iu chnh cho vng gi tr sai lch nh nht ca Zfault. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Q[T] Flow = Constant

50 45 40 35 30 25

Max Level Min Level

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20 15 10 5 41 42 43 44 45 46 47 48 49 50 Hnh 3.10. Quan h v tr van v trng lng kt cn Zm[%]

Tnh tc : Tn s iu khin tc ca ng c c th c iu chnh trong 1 khong n 100Hz, n c th c c trc b bin tn. Vi mc tn s thp ny c th chy ng c m khng cn dng v khi ng. tnh tc , bin Znew c dng, cng nh tc t cho h thng. Khu khuch i KP3 s dng gi tr c nh, v ch thay i gia hai i lng %/sec v Hz.
KP3 = f . dZ dT

i lng ny c th c tnh d dng, bng cch chy tho liu lin tc ti tn s nh trc. Tnh lu lng:

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Trong chu k rng mt dn trng lng, lu lng c o. iu ny khng th lm trong chu k y, khi cng thc ton c dng tnh lng c dng sau:
F= Z [T / h] X 1 + X 2 .Q + X 3 .Q 2

Vic tnh lu lng tc thi tng ng vi vic o v tr v trng lng ca kt cn. Lu lng tnh c phi cho qua b lc loi b nhng dao ng trc v sau khi kt thc mt chu k, n c th hin lu lng thc t v trng lng tch lu trn hnh v. * Ch bng tay (Hnh 3.11): Trong ch ny h thng mt trng lng s v tr khng hot ng. Ngi vn hnh c th a ra im t bng tay cho v tr van tho (Zmanu), v ng c s c iu khin ng vi v tr t. Phn tnh ton lu lng cng ging nh ch t ng. Thm ch nu ch ny c duy tr trong mt thi gian di, vic tnh lu lng s tnh c ng cho c chu k y do cc bin h thng lun c cp nht.

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3. H thng iu khin ch nhit cho calciner 3.1. iu khin qu trnh chy trong calciner: Bi ton iu khin qu trnh chy trong bung phn hu l mt bi ton phc tp. Vic iu khin ph thuc vo rt nhiu tham s nh: - ng nht ca liu. - Cht lng than. - Lu lng gi. - Nng CO, O2, - S phn phi kh. - Hiu qu ca cyclone. Vic iu khin qu trnh chy trong bung phn hu c thc hin nh sau: Khng kh cp cho bung phn hu c ly t h thng lm ngui clinke qua ng gi 3, mt phn gi c trch ln tng trn ca bung phn hu (gi 4). Kh phun m v vn chuyn nhin liu. Gi 3 v gi 4 l kh mi trng t my lm ngui c trao i nhit vi clinke. Nhit ca gi s ph thuc vo hiu qu ca b lm ngui, t khong 7500C 9000C. Kh phun m v vn chuyn nhin liu l kh cn thit cho bt than mn v lm ngui thit b vi t. Lng kh tha l 20% tng ng 4% xi trong ng thot ca bung phn hu m bo cho than chy ht. Nhin liu c cp cho bung phn hu chim khong 60% tng lng t to clinke. Nhit trong bung phn hu khong 10000C, thi gian lu ca kh chy trong bung phn hu khong > 4s. Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Sau cyclone A54, van A71 chia bt liu thnh hai nhnh, nhnh th nht i thng xung l, nhnh th hai i vo bung phn hu vi mc ch l iu chnh nhit bung phn hu, iu chnh lng canxi ho thch hp trc khi liu vo l nung v iu chnh s c xy ra vi bung phn hu. Bt liu i vo bung phn hu cng c van A73 chia thnh 2 nhnh, nhnh th nht i vo tng trn, nhnh th hai i vo tng di, nh vy m ta c th iu chnh nhit trong bung phn hu. Nhit im o A56T1 l tham s cho mch vng iu chnh van A71. Bung phn hu c t hon ton bng than nu van A71 m nh nht l 20% v vi t du nng, tc l s c 20% liu i vo ng ng ca l v 80% liu i vo bung phn hu. Do vy khi t hon ton bng than th yu cu lng liu cp cho bung phn hu < 80%. Nhit im o A56T1 cng cao th van A71 m cng nh v ngc li. Nu A56T1 > 10500C th bo li gim t t cp than. Nu A56T1 > 11000C th ngng cp than. Nhit A56T3 lm tham s cho mch vng iu khin van A73. m ca van A73 th hin lng liu cp vo tng trn ca bung phn hu, A56T3 cng cao th van A73 m cng nh. My phn tch kh thi: Cc thit b phn tch kh lin tc ly mu khi l cung cp thng tin v mc O 2, CO v NO cho ngi vn hnh trn c s ny iu khin lung khng kh tha trong l. Kh thi khng c cha kh d chy: CO, H2,Khi lng kh tha trong l nh hng n tiu th nhit v hot ng Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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ca l. Nu kh thi cha kh d chy th qu trnh t than cha hon ton. Kh thi cng cha nhit ca n. Khi lng nhit ny b tn hao trong kh thi cng ng k. Trong kh thi m tha 1% CO th trong l phi tiu th thm 40kcal cho 1kg clinke. V vy m bo an ton phi trnh kh cha chy trong kh thi. Khng th nhn thy c kh cha chy nhng nu qu trnh t chy din ra km th khi en s hnh thnh cc ho v mui. Thng thng qu trnh t chy khng hon ton l do thiu kh. Tuy nhin qu trnh t chy khng hon ton cng c th xy ra mc d c lng kh v hm lng xi. iu ny cng c th xy ra nu mt s kh d chy gp kh chy nh l v qu ngui khng th chy c. Cng c th xy ra nu ngun cp nhin liu khng u, do vy nhng thi im no c th cung cp qu nhiu cho qu trnh chy. Kh tha: Lng kh tha khng c nhiu qu v nu nhiu kh tha qu s lm gim nhit trong zn nung v tng tc kh qua l do lm mt nhiu bi. Nhit b di chuyn ln pha trn l, iu ny c th gy ra nhit qu cao trong cc cyclone. Nu lng kh thi qu nhiu th tn hao nhit cng nhiu v thit hi v kinh t. Ngoi ra cn lm tng ti qut ID. Thiu kh: Thiu kh dn ti t chy khng hon ton v lm gim nhit zn nung. Mt phn kh cha chy v nhin liu tp trung trong thp trao i nhit, cc b lc bi v ng dn ni m trong nhng trng hp ri ro chng c th bc chy v n. Nhin liu khng chy trong kh thi li Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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lm tng mc tiu th nng lng ca l. N cng lm tng kh nng hnh thnh cla trong u vo ca l. Lng kh tha c iu khin sao cho bao gi cng c mt lng kh tha so vi tc bt than cp vo l. iu ny c thc hin da trn hm lng xi u vo ca l. Nn c gng gi cho hm lng xi khng i bng cch thay i vn tc qut kh hoc thay i v tr van iu tit qut. Qu trnh ny c thc hin nh cc mch vng iu chnh PID. 3.2. iu khin nhit bung phn hu: Bi ton iu khin nhit bung phn hu l mt ton rt quan trng, yu cu iu khin y l phi m bo sao cho liu sau khi ra khi bung phn hu t mc canxi ho 90% - 95%. Hm lng canxi ho t c trong bi ton ny c nh hng rt ln n bi ton iu khin zn nung. N quyt nh n ch hot ng ca zn nung. m bo liu ra khi bung phn hu t mc canxi ho 90% - 95% ta phi m bo c cc thng s hot ng v nhit , p sut nh hnh 3.12. Vic iu khin nhit bung phn hu A56 c thc hin qua cc mch vng iu khin t ng sau: - Tn hiu W2A55T1_PID1 iu khin: W2V21Y1_Z11 (v tr) - Tn hiu W2A55T1_PID2 iu khin: W2V82Y1_F11 (im t) - Tn hiu W2A56T2_PID iu khin: W2V31Y1_Z11 (v tr)

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- Tn hiu W2A56T8_PID iu khin: W2A73M1 (v tr) - Tn hiu W2A56T1_PID iu khin: W2A71M1 (v tr) Trong W2V21 v W2V31 l cc van du, do h thng l c t bng than nn vic iu khin nhit ch cn mch vng iu khin t ng W2A55T1_PID2 iu khin im t cho cn quay cp than W2V82. Cu to v hot ng ca cn cp than Pfister Ta bit than cp cho bung phn hu A56 c iu khin bng mch vng t ng W2A55T1_PID2 iu khin im t cho cn quay W2V82. H thng cp than cho bung phn hu bao gm: - Sil cha than W2L11, ng c khuy W2V70. - Van kh nn W2V81, W2V84, W2V86. - Qut gi W2V83M2, W2V85M2. - ng c quay ng to gi W2V83M1, W2V85M1. - Cn quay W2V82. c phn b nh hnh 3.14. Than trong sil W2L11 nh b khuy W2V70 chy qua van ng m W2V81 xung cn quay W2V82. Gi t qut W2V83 qua van kh nn W2V84 thi vo cn quay W2V82 a than cp cho bung phn hu. Cc van W2V84 v WV86 c tc dng ng m. Gi thi vo bung phn hu c to ra t hai nhnh, trong mt thi im ch c mt nhnh hot ng cn mt nhnh d phng. Nhnh bn phi gm qut gi W2V83 v van W2V84 l nhnh hot ng chnh.

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Tc cp than c iu chnh bng tc quay ca a tc l thay i tc ca ng c quay a. Lu lng than cp cho bung phn hu ph thuc vo nhit nh A55T1. Nhit lm tham s cho mch vng PID iu khin ng c cp than V82. A55T1 cng cao th V82 m cng nh. Tc quay ca V82 th hin lng than cp cho bung phn hu. Nhit A55T1 c o lm thng s thc cho b iu khin qu trnh PIDCON. im t nhit t t bn phm ca ngi vn hnh. u ra ca b PIDCON s quyt nh gc m cho b chnh lu dng Thyristor. T iu chnh in p cp cho ng c cn quay than W2V82.

Than

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Sil cha than mn L11 W2V72 A56 Than W2V82 M M P W2V81

W2V86 P

W2V84 P

W2V85 M

W2V83 M

Hnh 3.14. S h thng cp than cho bung phn hu

4. H thng iu khin b lm ngui kiu ghi ca HT II 4.1. Lm ngui v c tnh ca clinke: Vic iu khin b lm ngui clinke l mt phn quan trng trong phn x l nhit ca h thng l bi v n nh hng trc tip n cht lng clinke ra l. Trong phn s hnh Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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thnh v c tnh ca clinke ta bit trong zn lm ngui c cc phn ng ho hc xy ra. T l qung C 3S lun gim i trong khi lm ngui, v s lm ngui cng chm th mc gim cng ln, mt s qung s chuyn thnh C 2S. S thay i v mi quan h gia C3S v C2S s nh hng n vic nghin clinke v C2S kh nghin hn C3S. Cch thc lm ngui clinke cng nh hng rt nhiu n cht lng ca n. S lm ngui nhanh s nh hng tch cc n cht lng clinke cng nh n kh nng nghin. Ngoi ra nu chng ta to ra c mt dng i lu hon ho trong vic trao i nhit gia clinke v khng kh th hu nh ton b nhit lng trong clinke c th c chuyn qua kh t. V th b lm ngui c kh nng gim nhit nng tiu th nhiu nht. Hn na clinke ngui vn chuyn d dng hn. Kch c ht ca clinke rt quan trng i vi s hot ng ca bt c b lm mt no. Khng c c qu nhiu bi, t hn 15% c d 0,5mm l tt. Nu c qu nhiu clinke c kch c 25mm lm tng nhit ca clinke sau khi lm mt v lm mt nhit ny tn rt nhiu thi gian. t hn 10% l tt nht. Bi clinke c xu hng b thi ngc li l to thnh s lun chuyn ca bi gia l v b phn lm mt. Bi ny c th lm nh hng n s lan truyn ca ngn la trong l v thng lm o ln s hnh thnh clinke, do s lun chuyn ca bi c xu hng tng ln.

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S lun chuyn ca bi lm cho nhit lng ca clinke i vo b lm mt tng ln, do s lm gim hiu sut ca b lm mt. T nhng phn tch trn ta s rt ra c chin lc iu khin b lm ngui clinke sao cho cht lng clinke tt nht, m bo hot ng tt cho cc thit b v gim lng tiu th nng lng xung nh nht. S h thng hnh 3.15. 4.2. H thng iu khin tc ghi: Lu lng gi qua cc ghi ng c iu tit nh h thng thu lc iu khin s dch chuyn ca ghi. Lu lng gi qua ghi ph thuc vo lng clinke dy hay mng trn ghi. dy ca clinke li ph thuc vo tc ca ghi. Mt vng iu khin c thc hin nh vic o p sut di ghi iu khin chuyn ng ca cc xi lanh thu lc. Vy tc ca ghi s tc ng n nhit v nng sut lm ngui ca clinke. Tc v thi gian chuyn ng ca ghi phi c kim sot. Di cc thanh ghi ca b lm ngui c chia thnh mt s khoang, mi khoang c qut c trang b cc cnh dn hng c th iu chnh c iu khin lu lng kh t ng v in nng tiu th ti thiu. Clinke chy trn qua ghi c thu vo cc phu v a qua cc van lt kn kh ti bng ti clinke. S di chuyn ca ghi c iu khin bi bm chnh, bm du theo 2 hng. Du bm t ca A y ghi tin cn bm t ca B y ghi ngc li. Trn cylinder c mt van ng/m (Shuttle valve). Chc nng ca van ny l bt i mt phn du dng di chuyn ghi. Trn bm chnh c Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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2 bm nh. Mt bm l bm tng cng, dng in y th tch du m van ng/m ly i. Bm th 2 dng bm du ti mt h thng dn hng dng iu khin dng du t bm chnh. Bm chnh l bm piston roto hng trc. H thng ph bao gm mt van t l iu khin bng in. Ghi th 2 dng mi cylinder mi bn ca ghi, lm vic theo ch master/slave. Ghi 1 ch dng mt cylinder ng trc ca ghi. 4.3. H thng iu khin lu lng gi: Vng iu khin lu lng gi trn ghi bng cch o p sut u b lm ngui iu khin van gi ca ht on ghi pha sau. Nh m lu lng gi qua h thng ghi c iu chnh lm thay i lm thay i p sut trn ghi. Qut ny cn tc ng n lu lng gi 2 vo l. h thng iu khin tin cy v n gin th n phi m bo 3 chc nng: - Lu lng kh khng i cho mi bung di ghi. - p thp khng i trong ng chp l. - p sut thp di khoang thanh ghi th nht. 4.4. H thng iu khin t ng h thng phun nc: Vng iu khin nc phun thc hin bng b PID, nu nhit kh trc b lc cn ln hn 300 0C th vi phun nc c t ng m, mi bn 3 vi ti nc vo clinke m bo nhit clinke ra l ng yu cu ng thi cng bo v b lc bi tnh in khi hng v nhit. Vn quan trng ca b lc bi ghi l x l v lc bi kh tha. Kh tha thay i v s lng, nhit , hm lng

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bi, v vy h thng x l phi c thit k cho iu kin xu nht.

5. H thng iu khin ch kh ng hc 5.1. Tng quan: Chng ta thy m bo lng gi trong l cho qu trnh hnh thnh clinke v qu trnh t chy nhin liu cn phi to ra c p sut ph hp tng im trong l. Hnh 3.12 trnh by cc thng s v p sut trong h thng l. C th chia h thng tc ng n p sut trong l lm cc h thng sau: Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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H thng cc qut gi kh thi ng sau thp trao i nhit : J15, P27. H thng cc qut gi tc ng n p sut trong bung phn hu: qut gi cho ng phn hi A77 (qut gi 3), qut gi A74 cho ng ng ca l, qut gi V22 trc tip vo ngn di ca bung phn hu. H thng cc qut gi 1 ca vi t tc ng trc tip n ngn la trong l: V91, V93. H thng cc qut gi cho b lm ngui clinke: trong quan trng nht l qut kh thi J15 v qut kh b lc bi P27. Qut J15 to ra p sut m trong h thng thp trao i nhit. Qut P27 to p sut m u l tc ng vo lung gi 2. Ngi ta c th thay v iu khin tc qut J15 bng cch iu khin v tr m ca van gi J14, qut P27 bng van gi P26. Cc qut gi cung cp kh t cho bung phn hu cng nh ng l A74, V22 thng c gi n nh tc n nh qu trnh t. Ch yu l iu khin v tr m ca cc van gi J14 v V27. Bi ton iu khin p sut ph thuc vo yu cu ca bi ton iu khin nhit , n c thc hin bng cc vng PID nh trn hnh 3.16.

5.2. iu khin van iu tit qut kh tha ra khi b lm ngui (P26, P27): p sut u l c dng lm thng s iu khin van iu tit ca qut kh tha sau b lm ngui vi mc Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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ch gi cho p sut m u l l khng i, iu ny gip cho vic iu tit lng gi 2 ph hp theo yu cu ca iu khin t. p sut u ra ca qut kh thi J15 c dng lm thng s iu khin tc ca qut kh tha sau b lm ngui P27 nhm duy tr p sut m ti u ra ca qut kh thi khng i ti mt im t nht nh, thng l -5mm ct nc. 5.3. iu khin van iu tit ca qut kh thi J15: Lng kh thi ra khi thp trao i nhit phi c iu khin gi cho lng xi ra khi thp trao i nhit khng thay i. ng thi n phi m bo c cc thng s p sut ti cc im o trn thp trao i nhit.

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Chng 4 : M phng h thng iu khin cp liu cho l nung

1. xy dng m hnh ton hc ca kt cn Trng lng Q c liu ca kt cn c tnh theo cng thc:
Q = S .H .

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Trong :

S l thit din kt cn (khng i). H l cao ca liu trong kt cn.

l trng lng ring ca bt liu (khng i).

Lu lng ra khi kt cn c tnh theo cng thc:

F= dQ dt F = S . . 1 Fdt T H= 1 F Ts dH dt

Thay Q vo ta c: t T = S .
H =

Chuyn sang min Laplace:

Ta nhn nh Q v H c quan h tng ng. Vy m hnh ca kt cn chnh l khu tch phn, ta phi xc nh hng s T da vo cc thng s ca kt cn. Trong qu trnh hot ng, trng lng kt cn thay i do hai lu lng: - Lu lng liu rt ra Fr = Fsp khng i chnh l lu lng cn thit cp cho l nung. - Lu lng liu tho vo cng khng i nhng ph thuc vo trng lng ca kt cn. Khi trng lng ca kt cn Q = Qmin liu s c tho xung kt cn, khi Q = Q max th van tho ng li. Chu k tho liu ny chnh l chu k cht liu. Trong chu k rt ch c vic rt liu ra khi kt cn. Da vo thng s c th ca chu k ny ta xc nh hng s T. Trong s hnh 3.10 m t s ph thuc ca Q vo v tr van rt liu, ta xc nh c trng lng t cho kt cn: Qmax = 40T Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Qmin = 30T Trng lng ti a ca kt cn l 50T ng vi di tn hiu in p o c l 0 10V, vy dng in p l: Qmax = 8V Qmin = 6V Lu lng t liu cp cho l nung Hong Thch II l Fsp = 200T/h trong di iu chnh 0 300T/h, ng vi in p Fsp = 6,67V trong di 0 10V Vi lu lng t trong khong thi gian rt liu l 180s, trng lng kt cn st t Qmax Qmin tc 10T tng ng vi 2V. t c yu cu trn th chng phi c dc nh nhau:
Fsp 2 = T = 600 s T 180

Vy m hnh kt cn l:
WC = 1 600 s

c tnh ca trng lng kt cn minh ho trn hnh sau:

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0 180 300

t(s))

Hnh 4.3. c tnh trng lng kt cn trong mt chu k xc nh c lu lng tho vo kt, ta da vo c tnh trong chu k cht liu. Thi gian o c trong chu k cht liu vi lu lng tho nh trn khong 120s. Trong thi gian ny trng lng kt tng t Qmin n Qmax, vy ta c: Qnp = Qrt + 10T = 6,67T + 10T = 16,67T Suy ra lu lng tho: Fv = 500T/h tng ng vi in p t 16,67V. iu khin liu np vo kt, ta s dng mt khu so snh gii hn bi Qmax, Qmin. S khi m phng kt cn trn hnh 4.4.

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Qstart

Fsp

+ -

1 600s

Fv Hnh 4.4. S khi m phng kt cn

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2. Xy dng m hnh ton hc h truyn ng bin tn - ng c khng ng b ba pha ng c iu khin van rt liu kt cn gm ng c W2A03 cho ca A v ng c W2B03 cho ca B. Chng c cc thng s sau: Cng sut danh nh: PN = 0,13KW. Tc ti a: in p pha: Tn s hot ng: H s cng sut: nmax = 630v/p. U = 380V. 50Hz.
cos = 0,85.

Dng pha danh nh: IN = 11.6A. l nhng ng c c bit, c th hot ng vi di tn s t 0 100Hz. V mt l thuyt ta c th ta c th xy dng c m hnh ton hc cho h truyn ng bin tn ng c da vo cc thng s danh nh. Tuy nhin vic lm s rt phc tp m cha chc cho kt qu ng mong mun. Mc ch ca phn ny ch m phng thy r nguyn l hot ng ca h thng iu khin cp liu cho l nung. V vy y ta s xy dng m hnh ton hc ca h truyn ng bin tn - ng c theo c tnh ca n.

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Hnh 4.9 l th c tnh theo thi gian ca h c dng xung tam gic, do vy m hnh ton hc ca h s l mt khu tch phn:
Wh ( s ) = 1 Th s

Z 5 4

t 180 300

Hnh 4.9. c tnh ca v tr van ca rt liu

Trong chu k rt liu, in p u vo tng t ca bin tn o c: Vm = 0,5V Ta c : 180 = T Th = 90 h

m hnh ton hc ca h truyn ng bin tn - ng 1 0,5

c l:
Wh ( s ) = 1 90 s 94

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3.M phng h thng iu khin cn cp liu l nung S m phng h thng iu khin cn cp liu l nung trn simulink nh hnh 4.10. Vi lu lng t 200T/h, ta c c tnh ca Fv, Fr, Q, Zsp, Zm nh trn cc hnh 4.11, 4.12, 4.13, 4.14, 4.15.

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Fv

t(s) Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Hnh 4.11. Tn hiu lu lng vo kt cn

Fr

t(s) Hnh 4.12. Tn hiu lu lng ra kt cn

Q t(s) Sinh vin thc hin: Hong Minh Sng Lp KT2 K46

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Hnh 4.13. Tn hiu trng lng kt cn

Zsp

t(s) Hnh 4.14. Tn hiu v tr t van iu khin

Zm t(s) Sinh vin 4.15. thc Tn hin: Hong Sng iu Lp KT2 Hnh hiu v trMinh o ca van khinK46

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Khi lu lng t thay i, lu lng ra cng p ng theo, ng thi v tr van cng thay i ph hp. T hnh 4.16 n 4.20 trnh by cc tn hiu khi Fsp = 4, t hnh 4.21 n 4.25 trnh by cc tn hiu khi Fsp = 8. - Khi Fsp = 4.

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Fv

t(s) Hnh 4.16. Tn hiu lu lng vo kt cn

Fr

t(s) Hnh 4.17. Tn hiu lu lng ra kt cn Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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t(s) Hnh 4.18. Tn hiu trng lng kt cn

Zsp

t(s) Hnh 4.19. Tn hiu v tr t van iu khin

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Zm

t(s) Hnh 4.20. Tn hiu v tr o ca van iu khin - Khi Fs = 8.

Fv

t(s) Hnh 4.21. Tn hiu lu lng vo kt cn Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Fr

t(s) Hnh 4.22. Tn hiu lu lng ra kt cn

t(s) Hnh 4.23. Tn hiu trng lng kt cn Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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Zsp

t(s) Hnh 4.24. Tn hiu t v tr van iu khin

Zm

t(s) Hnh 4.25. Tn hiu v tr o ca van iu khin Sinh vin thc hin: Hong Minh Sng Lp KT2 K46
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