Sinoma Energy Saving:

Innovative technology to help energy saving and emission reduction

Building materials industry is a traditional high energy-consuming industry in China. As the third largest energy-consuming industry after metallurgy and chemical industry, it accounts for about 7% of the total energy consumption in China, while the energy consumption of cement enterprises reaches 75% of the energy consumption of building materials industry. Under the situation of increasingly strict national energy conservation and environmental protection policies, improving waste heat recovery and utilization has become an important means of energy conservation and emission reduction in cement and other industries. Today, with the intelligent development of global industrial manufacturing, Sinoma Energy Conservation adheres to the core concept of "making good use of resources and service construction", and constantly makes "intelligence" and "innovation" a new label for waste heat power generation technology.

From Forerunner to Leader

In the 1980 s, high energy-consuming and high-emission industries developed rapidly, and the exhaust emissions polluted the environment and wasted resources. In this situation, the cement waste heat power generation for the fist business of Sinoma energy saving came into being.

Waste heat power generation technology refers to the industrial production process of cement, steel, coking, carbon, industrial silicon, gas turbine, etc., a large amount of waste gas waste heat discharged from production is recovered through a waste heat boiler, and the steam generated by the waste heat boiler is used to drive the steam turbine to do work and drive the generator to generate electricity. Technology.

Since undertaking the national "Eighth Five-Year Plan" scientific and technological research plan, Sinoma Energy Conservation has always been committed to the research of waste heat power generation technology in cement plants. With the historical transformation of cement production technology from vertical kiln, hollow kiln, wet rotary kiln to dry rotary kiln, cement waste heat power generation technology has also experienced the development process from high temperature, with supplementary combustion to pure low temperature.

In recent years, with the proposal of sustainable development, circular economy, energy conservation and emission reduction and low-carbon economy, Sinoma's territory in the field of energy-saving waste heat power generation has been continuously extended, and its leading position in the industry has become increasingly prominent. By the National Development and Reform Commission, the Ministry of Finance for the record, Sinoma Energy Conservation has become a national energy-saving service enterprises. As a high-tech enterprise, Sinoma Energy Conservation has a national-level enterprise technology center and a national engineering laboratory. It has won the second prize of the National Science and Technology Progress Award. It has edited and participated in the compilation of dozens of standards, and has consulting, design, and general engineering contracting. Many qualifications.

After more than 20 years of innovation and development, Sinoma Energy Conservation has obtained a number of patents and proprietary technologies with complete independent intellectual property rights in the field of waste heat power generation. Among them, the pure low-temperature waste heat power generation technology in the fields of cement, steel, and chemical industry has reached the international advanced level. During the period, Sinoma Energy Conservation has successively undertaken the "Eleventh Five-Year" National Science and Technology Support Plan, the "Twelfth Five-Year" National Science and Technology Support Plan, Tianjin Science and Technology Innovation Special Fund (Mayor's Fund), Tianjin "Killer" products, etc. National and provincial-level science and technology projects have always led the most advanced technology of cement kiln waste heat power generation.

In the domestic market, Sinoma Energy Saving has designed and equipped low-temperature waste heat power generation systems for more than 400 cement kiln production lines at home and abroad, with a domestic market share of 22.95 percent, leading the way; in the international market, Sinoma Energy Saving has always actively implemented the "going out" and "Belt and Road Initiative" initiative, and is one of the earliest enterprises in the domestic industry to enter the international market. It is a leading service provider in the overseas cement waste heat power generation market. Sinoma Energy Conservation has become a well-deserved pioneer and leader in the field of global cement kiln waste heat power generation.

Innovative Technology Enabling Waste Heat Power Generation

Passive, active, "integrated" development. In terms of technological innovation and technological progress in waste heat power generation, Sinoma Energy Conservation has always been at the forefront. The previous waste heat power generation, as an ancillary product of the cement production line, was a passive project. In the research of the latest generation of cement kiln waste heat power generation, Sinoma energy-saving breaks the shackles of traditional concepts and changes passivity into initiative. For the first time, a new concept of integration design of waste heat power generation and cement process is proposed. The waste heat boiler is a part of the cement production line, which is a bold attempt to improve the layout of the boiler and improve the performance of the equipment.

The latest generation of cement kiln waste heat power generation technology organically integrates waste heat power generation and clinker production line process, cancels the air cooler in the traditional cement process, and makes the AQC waste heat boiler operate in series with the production line, which can make full use of waste gas waste heat and ensure the safe operation of subsequent dust collection and other equipment. In terms of layout, the AQC waste heat boiler shares the foundation and platform with the production line. The boiler adopts the lower air inlet, which is directly arranged above the grate cooler and connected with its middle part. The air inlet pipe is short, the temperature and pressure loss are small, and the system runs very smoothly. In addition, because the boiler adopts the lower air inlet, the ash in the flue gas directly falls back to the grate cooler under the action of gravity, so that the ash hopper, feeder, zipper machine and other ash unloading equipment can be canceled.

The air intake pipe of kiln head boiler shall take effective measures to ensure that the flue gas temperature at the boiler inlet is quickly reduced under abnormal kiln conditions, so as to protect the boiler flue and furnace body from damage due to high temperature. In addition, the boiler is provided with flow-equating plates, anti-wear covers, etc., which can further prevent the large particles of clinker dust entrained in the flue gas from entering the furnace body, thereby slowing down the wear of the heating surface and ensuring the heat transfer effect.

The waste heat boiler at the kiln tail takes air from the C1 air outlet of the preheater and operates in series with the kiln system. The exhaust gas is discharged into the high temperature fan after heat exchange through the waste heat boiler at the kiln end from top to bottom, and the side ventilation pipe is arranged outside the boiler. The water spray cooling system is canceled for the kiln tail exhaust gas treatment. Considering the heat requirements for the tail such as raw mill drying, the kiln tail SP boiler adopts a double-pressure system with a designed exhaust gas temperature ≥ 180 ℃ and is adjustable.

Improve efficiency, ensure operation, "steady" win. With the promotion of the second-generation cement clinker calcination technology, the fourth-generation grate cooler and six-stage preheater with central roller break have gradually become the regular configuration of the new cement plant. For the upgrading of cement technology and equipment, Sinoma Energy Conservation actively explores new technologies for waste heat power generation and develops new energy-saving equipment that matches them. For example, for the low outlet temperature of the six-stage preheater C1, the new generation of waste heat power generation technology adopts a combined superheating system and uses hot air from the kiln head to heat the low-quality steam generated by the kiln tail boiler, thus realizing the cascade utilization of waste heat resources and effectively improving the thermodynamic cycle efficiency of the power station; in order to reduce the loss of working fluid when the steam turbine starts and stops, and to ensure the normal operation of the steam-water circulation system and the waste heat boiler when the steam turbine fails, the new generation waste heat power generation technology introduces 100 large bypass system of the steam turbine, thus realizing shutdown and ensuring that cement production is not affected. In order to maintain the vacuum of the condenser, the new generation of waste heat power generation technology adopts the full-automatic liquid ring vacuum pumping device independently developed by Sinoma energy, which is matched with high-efficient vacuum pump and condensing system, through PLC control and establish communication with DCS, so as to realize automatic operation and achieve the purpose of energy saving and water saving. All these measures have laid a solid foundation for improving the overall efficiency of the unit and ensuring the safe and stable operation of the power station.

Save manpower, increase efficiency, "smart" build upgrade. With the proposal of high-quality development requirements, Sinoma Energy Saving keeps pace with the times and actively explores new technologies of high automation and intelligence for waste heat power stations. The new generation of waste heat power generation system adopts advanced wireless communication technology to collect power station operation data to realize remote big data analysis and management. By setting up a large number of cameras to monitor the whole waste heat power station in all directions, it can pay attention to the power station status in real time and give timely operation and maintenance guidance. The new generation of waste heat power generation technology is equipped with a large number of electric or pneumatic steam and water valves, and the online sampling system of boiler water, condensate water and feed water and the automatic dosing device of boiler drum are introduced, so as to achieve the purpose of reducing staff and increasing efficiency. By optimizing the power station regulation circuit and DEH system, the automatic control of the process of unit rotation, speed increase, warm-up, grid connection, load regulation and normal shutdown is realized. The above measures are helpful to realize the one-key start-up and quasi-unattended operation of the subsystem, which greatly improves the automation and intelligence level of the waste heat power station.

Quality engineering to enhance brand value

With the most hard core technology and the most advanced concept, Sinoma Energy Saving has created a number of benchmark cement waste heat power generation projects.

Huzhou Huaikan Waste Heat Power Generation Project is a 7500t/d cement clinker production line with pure low-temperature waste heat power station with an installed capacity of 13MW steam turbine and 15MW generator under the national sustainable development strategy and comprehensive resource utilization policy. This project is by far the shortest construction period, the highest automation program and the leading waste heat power generation project in the industry.

Since the trial operation of Huzhou Huai Cha Project at the end of 2019, the main body has been running well. Under the premise of 638.82kcal/kg per unit clinker heat consumption and 40.31kWh/t.cl clinker comprehensive power consumption, the power generation per ton of clinker is more than 29kWh/t.cl, which is better than the assessment index and reaches the best level in the industry in the cement clinker production line equipped with six-stage preheater. The project uses advanced automation equipment to replace labor, greatly reducing the use of manpower, and significantly improving work efficiency; the equipment adopts domestic first-class equipment to ensure the quality of the project, maximize the recovery of waste heat, reduce energy consumption, and increase power generation. The proportion of station electricity consumption is also maintained at a low level, which perfectly interprets the service tenet of "low energy consumption and high output" of Sinoma energy saving.

Tongchuan Yaobai waste heat power generation project is a set of pure low-temperature waste heat power station supporting the construction of the first intelligent cement 10,000-ton demonstration production line in the western region, with an installed capacity of 15MW. As the cement production line with the most advanced technology, the highest environmental protection level and the highest construction standard in the history of Yaobai, the waste heat power generation system constructed by Sinoma Energy Saving is one of the important components. The latest generation power generation technology is adopted to organically integrate the waste heat boiler and the cement production line. Under the premise of the operation of the six-stage preheater at the kiln end, the power generation per ton of clinker is more than 28kWh/t/t.cl, fully demonstrated the intelligent, green, energy-saving as the core of the global cement waste heat power generation cutting-edge technology.

Energy saving and emission reduction to help green development

Sinoma Energy Conservation is a listed company platform with specialized technical services for energy conservation and emission reduction under China National Building Materials Group. The previously put into operation waste heat power generation project has an annual power generation capacity of 26 billion kWh, and the annual carbon dioxide emissions can be reduced by about 20 million tons, which is equivalent to saving about standard coal. 7.6 million tons. At the critical moment of energy transformation, Sinoma energy-saving waste heat power generation has great potential.

Driven by the goal of "double carbon", Sinoma Energy Conservation has invested heavily in the development of new low-carbon technologies, new green materials and new environmental protection equipment, and actively explored and constructed a new model of integration of source, network, load and storage and multi-energy complementarity, including the research and development of new clean energy technologies, the development of composite energy storage technologies for industrial heat storage and electricity storage, the promotion of carbon dioxide capture, utilization and storage technologies, and production process innovation of new green wall materials-calcium silicate board, development and manufacture of high-efficiency photothermal equipment, etc.

Strive to achieve the cement clinker firing system purchased electricity "zero" breakthrough is the goal of Sinoma energy conservation has been struggling. In this regard, Sinoma Energy has increased its research and development efforts and studied the recovery and utilization of low-grade waste heat to maximize the utilization rate of waste heat resources in the whole plant. At the same time, according to the structural characteristics of the cement clinker firing workshop, it has introduced 5G big data application technology and a number of green and low-carbon new technologies such as solar energy, wind energy, geothermal energy and energy storage to further improve the intelligence level of the integrated power station and reduce the dependence of the firing system on the grid, so as to move towards the goal of "electric neutralization" of cement clinker firing system, and finally achieve the goal of energy saving and carbon reduction.