1. Internal Air Leakage in Preheater Systems
Many companies face problems with air leakage in the kiln tail preheater. From level I to level V, the flap dampers in the discharge pipes often malfunction. They may become stuck, fail to move, or not operate correctly, causing the dampers to remain open. This allows hot air from the lower stage to directly enter the upper preheater, resulting in a short circuit in the airflow. This issue is often hard to detect, but operators can sense pressure changes through manual testing.
1.1 Damper Open State
The dampers may remain open due to light weights on the counterweights or improper positioning. This results in insufficient pressure to close the dampers effectively.
1.2 Pressure Rod Suspended
Operators sometimes use wire to suspend the pressure rod, keeping the damper open. This usually happens when blockages frequently occur in the kiln. Addressing these blockages takes time and can lead to kiln shutdowns. To prevent large material from clogging the discharge pipe, operators resort to this method. Although it causes air leakage, it reduces the chances of blockage significantly. Over time, management may accept this practice, believing minor air leakage is acceptable as long as major operational problems do not arise.
1.3 Worn or Unlubricated Bearings
Worn bearings can hinder damper movement. If operators do not check or lubricate the bearings regularly, wear will accelerate.
1.4 Dust in Bearings
Poor sealing allows dust to enter the bearings, forming sludge with the oil, which can lead to the shaft seizing.
1.5 Worn or Detached Damper Plates
Damper plates may wear down over time due to material abrasion, especially at high temperatures, leading to improper closure and air leakage. In some cases, plates may break or fall off entirely.
1.6 Separation of Shaft and Damper Plate
Over time, the connection between the shaft and damper plate may loosen. This prevents the damper from moving with the shaft, compromising its ability to seal.
1.7 Risks of Internal Air Leakage
Malfunctioning dampers lead to incomplete closure, resulting in internal air leakage. This causes high-temperature gases from the lower preheater to short-circuit, reducing the effectiveness of raw material heating and lowering the quality of the clinker. It also increases thermal and coal consumption.
2. External Air Leakage
External air leakage occurs when ambient air enters the kiln and preheater systems through improper channels. This entry causes internal gas temperatures to drop and increases heat consumption. Major causes include poorly sealed kiln doors, observation holes, cleaning holes, and loose flange connections.
2.1 Air Leakage at the Kiln Head
Gaps between the kiln door and head can allow cold air to enter, reducing the front temperature and affecting coal combustion.
2.2 Air Leakage at the Kiln Head Seal
Worn seals or misaligned sealing mechanisms can create gaps that let cold air in, impacting the temperatures of secondary and tertiary air.
2.3 Deformation of the Kiln Mouth
Pursuing high operational rates blindly can lead to the loss of protective parts, compromising seals at the kiln mouth.
2.4 Poorly Sealed Inspection Holes
Operators may open inspection holes for convenience, failing to seal them properly afterward, which leads to significant air leakage.
2.5 Leakage at the Bottom of the Humidification Tower
Loose seals at the inspection holes in the humidification tower can let in cold air, affecting system pressure and increasing energy consumption.
3. Analysis of Leakage Causes
Air leakage is common in kiln and preheater systems, but many companies do not take it seriously. First, a lack of awareness about the dangers of air leakage leads to poor management. Second, many companies do not recognize the technical impacts of leakage and lack effective solutions.
4. Consequences of External Air Leakage
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4.1 Increased Heat Loss
Any point of air leakage can increase heat loss in the system, raising the energy consumption of clinker production.
4.2 Higher Electrical Consumption
Leakage forces the system to use more energy, increasing coal consumption and driving up electrical costs.
4.3 Lower Temperatures
Air leakage reduces temperatures in the kiln, disrupting thermal balance and affecting the quality of clinker.
4.4 Reduced Air Temperature and Volume
Leakage lowers the temperature of the incoming air, slowing coal combustion and affecting the quality of the clinker.
4.5 Clogging in Preheater Systems
Leakage can cause rapid temperature drops, leading to material hardening and clogging within the preheater and its pipes.
Заключение
Companies must prioritize addressing air leakage in cement kiln systems. They should enhance management practices, conduct regular inspections, and maintain good seals to improve production efficiency and product quality.
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