Abstract:To address the high failure rate,low heat recovery efficiency,and high energy consumption of a reciprocating push grate cooler in a cement production line,an upgrade was carried out by installing the walking-step high-efficiency grate cooler(W9830R19)with a central roller crusher.The upgrade involved replacing the core equipment of the clinker cooler,optimizing the crushing and lubrication systems,adjusting the fan configuration,and implementing advanced technologies such as efficient clinker distribution and rapid cooling,independent hydraulic drive,double-layer labyrinth seals,and IMCC intelligent control,along with the installation of flow control valves to achieve on-demand distribution of cooling air.After the upgrade,the effective area of the grate bed increased from 138m² to 169m²,the secondary air temperature reached≥1 150℃,the tertiary air temperature reached≥950℃,the heat recovery efficiency was≥75%,and the temperature of the clinker leaving the grate cooler was reduced to≤ambient temperature+65℃.The standard coal consumption per ton of clinker decreased by 2.68 kg/t.cl,and the power generation increased by 1～2kW·h/t.cl.The upgrade improved the operational stability of the system and energy utilization efficiency,achieving significant energy conservation and consumption reduction effects.

Abstract:To address the issues of reduced clinker strength and increased material consumption in a 6 000t/d cement production line caused by changes in raw materials and fuel,a specialized technical initiative was implemented.By strengthening quality control of raw materials and fuel,the project strictly regulated the MgO content in limestone,the alkali content in siliceous raw materials,and the stability of raw coal blending.The clinker three-ratio values were optimized to improve the burnability of raw meal.A 3.5%yellow phosphorus slag was added as a mineralizer to promote C3S formation and crystallization.Raw meal grinding aids were introduced to enhance particle size distribution and homogeneity.Precise control temperatures at the kiln inlet and outlet,tertiary air dampers,and grate cooler air supply ratios was implemented to improve calcination and cooling efficiency.Post-implementation results showed that the 3d clinker strength reached 33.4MPa(a 2.4MPa increase year-on-year),and the 28d strength reached 62.8MPa(a 3.2MPa increase year-on-year).The qualified rate of free calcium improved to 94.1%,achieving high-quality,efficient,and low-consumption operation of the kiln system.These measures also reduced corporate carbon emission pressure,providing technical support for sustainable development in the cement industry.

Abstract:The grate cooler,as a core equipment in the new dry-process cement clinker production line,directly affects the production system's output,energy consumption,and product quality.In response to issues such as excessive load on the grate cooler after the preheater system upgrade,leading to large fluctuations in the material layer,oscillations in fan current,frequent adjustments by operators,and instability of secondary and tertiary air temperatures,a lightweight expert control system for the grate cooler was developed based on thermal balance theory and multivariable control technology.By dividing the air volume control zones into high,medium,and low temperature sections,setting the standard air volume per unit of clinker,and integrating neural network modeling and model predictive algorithms,the system achieves adaptive cooperative regulation of the grate speed and fan air volume.Application results show that after system implementation,the average daily clinker output increased by 181t/d,standard coal consumption per ton of clinker decreased by 0.45kgce/t,waste heat boiler power generation increased by 0.94kW·h/t,and Pyro system power consumption decreased by 1.02kW·h/t.Moreover,fluctuations in secondary and tertiary air temperatures were significantly reduced,with substantial improvements in equipment operational stability and energy utilization efficiency,providing a technical reference for the optimization of similar equipment in the cement industry.

Abstract:To address the damage of key components in the rocker arm devices of TRM53.4 vertical roller mill during maintenance,a modular repair method utilizing similar semi-finished rocker arms was developed.This method focuses on redesigning and inlay welding critical parts including the roller ear plate and sealing frame's locating flange.CNC programming enables efficient rough machining of structural elements such as locating flanges and roller shaft holes.By optimizing cutting parameters and tool paths during processing,the method significantly reduces processing cycles for large critical components while maintaining repair quality,effectively meeting clients'urgent maintenance schedule demands.Practical validation confirms the strong feasibility of this integrated modular repair and efficient rough machining process.This solution not only reduces maintenance costs but also enhances repair efficiency,providing a reliable emergency repair solution for vertical roller mill rocker arms.

Abstract:To implement national policies on capacity management and green,low-carbon development in the cement industry,China Building Materials Federation took the lead in organizing,and CNBM Equipment Group(TCDRI)undertook the compilation of the group standard T/CBMF 367-2025"Monitoring and Accounting Method for Clinker Production in the Cement Industry."This standard was released on December 29,2025,and will take effect on February 1,2026.This standard establishes China's first comprehensive online monitoring and accounting system for cement clinker production covering daily,monthly,and annual data.It specifies requirements for data collection,calculation methods,error analysis,and management,filling a gap in China's standards for dynamic monitoring of cement clinker output.The standard employs a daily production calculation method primarily based on the"raw/clinker conversion factor method"supplemented by the"inventory change method."It introduces a monthly inventory adjustment mechanism and enhances data accuracy through annual material balance verification.The standard emphasizes standardized configuration of measuring instruments,data traceability,and online calibration to ensure production data is authentic,traceability,and consistency.Verified through production data from multiple enterprises,this scientifically sound calculation method will effectively support capacity regulation,carbon emission accounting,and high-quality development within the cement industry.

Abstract:A cement raw material mine in Tibet is located in a high-altitude environment.Constrained by factors such as extreme cold,oxygen deficiency,and inadequate local 4G network coverage,the traditional mining mode faces challenges including low production efficiency,high safety risks,extensive resource management and control,and weak digital infrastructure.In response to the national call for intelligent mine construction,the mine,centered on the in-depth integration of digital twin,Internet of Things,big data,and cloud computing technologies,has built an intelligent production management and control system cluster covering the entire chain of"geological resources-safe production-ecological protection"based on the"1+2+N"architecture system.This cluster includes 1 mine data center,2 intelligent management and control platforms,and N sets of safety monitoring systems,with its collaborative operation guaranteed by a five-layer architecture including the data acquisition layer and infrastructure layer,realizing digital mapping and real-time collaborative management and control of the entire mine production process.Practice has shown that the system cluster significantly improves the mine's mining efficiency and resource recovery rate,reduces the energy consumption per ton of ore and safety accident rate,and shortens the emergency response time.It has successfully overcome the technical adaptation problems of high-altitude mining,providing a replicable model for the construction of intelligent production management and control in high-altitude mines,and demonstrating important exemplary value for the efficient,safe,and green development of mineral resources in special environments.

Abstract:To investigate the influence of the arrangement form of tubular heat exchangers on the flow field uniformity characteristics inside the SCR reactor,this study adopts the numerical simulation method to compare and analyze the flow field characteristics under six heat exchanger arrangement forms,including the blank group(without heat exchange tubes),the matrix tube group,the staggered matrix tube group,the cross arrangement tube group,the transversely fully distributed tube group,as well as the combined scheme of matrix tube group and the flow distribution plate.Based on the Fluent software,the flow field inside the reactor is simulated.Taking the mass uniformity index of the catalyst inlet section(100mm above the catalyst surface)as the evaluation index,combined with the vortex structure visualization analysis based on the Q-criterion in Tecplot software,the causes of flow field inhomogeneity are revealed.The results show that the uniformity index of the blank group is 0.872;the uniformity indexes of the matrix tube group,staggered and cross arrangement schemes decrease to the range of 0.831 to 0.853;the uniformity index of the transversely fully distributed tube group is 0.892;while the combined scheme of matrix tube group and flow distribution plate achieves the optimal uniformity index of 0.946.The study confirms that it is difficult to achieve efficient flow equalization merely by adjusting the structure of heat exchange tubes,and it is necessary to coordinate with flow distribution devices.Considering the construction feasibility and maintenance space requirements comprehensively,the scheme of transversely fully distributed tube group-flow distribution plate is the optimal engineering solution.

Abstract:The grinding roller is the core component of the TRM vertical mill,and the grinding roller bearing,as a key part of the grinding roller,directly affects the normal operation of the mill and the stability of the production line,making maintenance work crucial.Proper lubrication is key to the maintenance of grinding roller bearings.Firstly,it is essential to clarify that the main lubrication methods employed are circulating lubrication and oil bath lubrication.The selection of suitable lubricating oil should be based on actual working conditions,and the inspection and replacement specifications for lubricating oil must be strictly followed.Secondly,ensuring the stable operation of grinding roller bearings requires attention to oil temperature control,vibration monitoring,and sealing quality.Oil temperature is managed in real-time through a dedicated monitoring system,vibration data is collected and analyzed using online monitoring and fault diagnosis systems,and sealing is achieved through a combination of lip seals and"V-ring seals+gas seals".Finally,the preparatory work and assembly precautions for the on-site assembly and maintenance of grinding roller bearings are detailed.It is also pointed out that factors such as vibration and overload operation during production can affect the service life of grinding roller bearings,necessitating targeted preventive measures to effectively extend their service cycle.

Abstract:In order to address the limitations of traditional slope terminology in open-pit mining and to compensate for the insufficiency of relying solely on the final slope angle in interpreting the slope risks during the mining process,this study systematically explores the practical value of introducing the concept of the sublevel slope angle through theoretical analysis and case study.The sublevel slope angle refers to the angle between a hypothetical slope plan formed by the benches at each mining level during the mining process and the horizontal plane.Together with the final slope angle,it constitutes the angles terminology of the non-working slope and exhibits process-related characteristics.Research indicates that this concept can enhance the terminology system in slope engineering,reduce ambiguity,improve communication efficiency,and dynamically reflect the accumulation of risks resulting from non-compliant practices during mining,such as exceeding the designed bench height or improper configuration of safety and cleaning berms.By analyzing a collapse accident case at an open-pit coal mine in Inner Mongolia,it is demonstrated that the introduction of the sublevel slope angle is useful to identify potential slope instability hazards timely and accurately.This concept provides an effective evaluation tool for both internal mining control and external safety supervision,holding significant importance for promoting the standardization and precision of slope safety management in open-pit mining.

Abstract:In order to increase early strength and achieving early demoulding in the production of precast concrete components.This study investigates the mechanical properties and hydration characteristics of a fly ash-cement system with fly ash(FA)contents under at 90℃steam curing.Results show that under steam curing conditions,the final compressive and flexural strength of pure cement mortar(0%FA specimen)are lower compared to those under standard curing,which is reduced by 15.41%and 28.27%,respectively.Similarly,the final compressive and flexural strength of the mortars containing fly ash(15%FA and 30%FA specimen)under steam curing conditions are also lower than those under standard curing conditions,which decreased by 4.27%and 13.90%for the 15%FA specimen,and by 4.16%and 9.32%for the 30%FA specimen,respectively.Especially when the fly ash content reaches 45%,there is no loss in final compressive strength or flexural strength but rather an increase by 13.71%and 26.8%,respectively.Furthermore steam curing not only promotes cement hydration rate but also enhances secondary hydration reaction between early-stage fly ash and calcium hydroxide.

Abstract:After the five-stage preheater of our company's 5 000t/d cement clinker production line was upgraded to a six-stage preheater,the SNCR denitration system encountered problems such as low denitration efficiency,increased nitrogen oxide emission concentration,and excessive ammonia water consumption,resulting in a significant increase in operating costs.To meet the emission concentration limit requirements and reduce operating costs,measures such as detection at each node,re-arrangement of spray guns,and trial-and-error elimination were taken.Through debugging and comparison of the SNCR denitration system,the set goals of reducing nitrogen oxide emission concentration,significantly reducing ammonia water consumption,and lowering operating costs were achieved.

Abstract:In 2022 and 2024,the National Mine Safety Administration successively issued the"Criteria for Determining Major Accident Hazards in Metal and Non-metal Mines"and its"Additional Items",providing an important basis for identifying mine safety hazards.However,in practice,some items still suffer from issues such as ambiguous judgment benchmark and insufficient quantified judgment criteria,which affect the accuracy and consistency of judgment.This paper focuses on metal&non-metal open-pit mines,analyzing the disputes and difficulties in standard implementation.Key areas of discussion include the treatment of goafs and karst caves,excessive slope angles and bench heights,signs of slope sliding,haul road gradients,waste dumptypes,and slope bench parameters.From the perspective of risk benchmarks,specific recommendations are proposed to refine and quantify the relevant items,aiming to enhance the accuracy,consistency,and operability of judgment.

Abstract:This paper addresses the harsh operating conditions of high temperature,high dust,and heavy load in cement industry by proposing,an intelligent equipment fault diagnosis technology based on vibration monitoring and spectrum analysis.It systematically reviews typical cases of predictive,maintenance for various key equipment in cement production analyzing them from four dimensions:fault phenomena,spectral characteristics,diagnostic conclusions,and maintenance feedback.Practical cases demonstrate that the intelligent diagnostic technology based on vibration monitoring and spectrum analysis can identify early faults such as bearing defects,misalignment,and gear damage in advance.Future research can further optimize fault feature extraction accuracy by combining deep learning algorithms and extend to the field of remaining useful life prediction for equipment,providing more comprehensive technical support for digital transformation of the cement industry.Furthermore,this methodology can be extended to heavy industries such as mining machinery and metallurgical equipment,facilitating high-quality development of the manufacturing industry.

Abstract:By selecting different types of solid waste samples for cement kiln co-pyrolysis experiments,the distribution patterns of sulfur and nitrogen in solid,liquid,and gas products were explored under the influence of different pyrolysis temperatures,residence times,carrier gas flow rate,and heating rate.Based on the principle of Back progatiom(BP)neural network and using Matlab neural network toolbox,a distribution model of pyrolysis product yield for different types of waste under different reaction conditions was established.The input conditions of the model are reaction conditions and sample characteristic parameters,and the output results are the proportion of sulfur and nitrogen in the three-state products.The predicted values of the model are in good agreement with the experimental values,and the accuracy of predicting the distribution of nitrogen and sulfur elements is high;Furthermore time,the composite algorithm was used to optimize the sample characteristic parameters of solid waste,and the sample composition and ratio were optimized.The results met the goal of sulfur and nitrogen control in cement kilns,indicating the feasibility and effectiveness of the model for simulating the pyrolysis process.

Abstract:The supporting roller shoes of rotary kilns are prone to overheating under long-term heavy loads,high temperatures,and alternating stress,significantly impacting equipment stability.The main causes of high temperature in supporting roller shoes include abnormalities in lubricant quality and quantity,insufficient cooling system efficiency,wear of the bearing bush,changes in liner plate clearance,abnormal operation of the hydraulic thrust roller,and misalignment of the kiln centerline.To address these issues,this paper proposes preventive and maintenance measures such as enhancing lubricant management,optimizing the cooling system,performing scraping repair on the bearing bush,adjusting the contact state of the supporting rollers,and regularly inspecting the kiln centerline.Additionally,a detailed emergency response plan has been developed.Practical cases demonstrate that systematic preventive and emergency measures can effectively control the temperature of the supporting roller shoes,ensure the long-term stable operation of the rotary kiln.

Abstract:During the operation of the ball mill cylinder,it is subjected to multiple complex loads,and the volume and weight of the cylinder is large,making it difficult to conduct modal analysis through experiments.This article takes the large ϕ5m×15m double sliding shoes ball mill as the research object,and uses finite element simulation software to perform modal simulation analysis on the cylinder.The first five modal parameters of the cylinder are obtained,and the operating frequency is calculated.Through analysis,the natural frequency of the cylinder is much higher than the operating frequency,and resonance phenomenon does not occur.Furthermore,through comparative simulation studies on the cylinder modal analysis of ball mills with and without double compartments,the presence or absence of double compartments has little impact on the change of the cylinder's natural frequency.

Abstract:The clinker production line experienced issues in the kiln system's grate cooler,including significant fluctuations in the secondary air temperature entering the kiln and the tertiary air temperature entering the precalciner,high coal consumption,and frequent burnout of the"cross bars"in the first section of the grate cooler.Analysis revealed that unstable material flow on the fixed grate bed was the primary cause.The proposed solutions included reducing the terrace height between the fixed grate and the horizontal grate,adjusting the step height,and rotating the entire fixed grate bed.After the modification,the material flow has become stable,the rapid cooling effect has been improved.The secondary and tertiary air temperatures have significantly increased with reduced fluctuations,coal consumption has decreased,the burnout issue of the"cross bars"has been largely resolved,the quality of clinker has been enhanced.The modification has achieved the expected objectives,effectively stabilizing the thermal regime of the kiln system,yielding remarkable economic benefits.

Abstract:To meet the increasingly stringent ultra-low NOX emission requirements in the cement industry(<50mg/Nm³),this paper takes a 5 000t/d cement production line as an example to introduce the principle and engineering application of calciner deep self-denitrification technology.This technology extends the residence time of NOX in the reduction zone,strengthens the control of the reducing atmosphere,improves the system's denitrification efficiency by raising the height of TAD inlet,expanding the volume of the reduction zone,optimizing the layout of the denitrification duct,and implementing a"separated air,separated coal,separated material'system design.After the retrofit,the NOX concentration at the outlet of the calciner system was reduced to 350mg/Nm³,ammonia consumption decreased to 2kg/t.cl,and standard coal consumption was reduced by 2kg/t.cl while maintaining the same clinker production,achieving both ultra-low NOX emissions and optimized operating cost.

Abstract:The pressure difference of the bag filter is an important parameter affecting its stable operation,and the pressure difference should be controlled within 1 500Pa.Taking the pressure difference control of low-pressure pulse bag filter in a refining furnace of a steel plant as an example,this paper analyzes the mechanical resistance and dust layer resistance as the main factors for the increase of the pressure difference of the filter through the simple resistance formula,and further analyzes the reasons for the increase of the pressure difference of the bag filter in the early stage of operation and in the process of use.By optimizing the air volume distribution of the dust removal point,adding interlocking control,reducing the filtration velocity,strengthening the dust removal mode and upgrading the filter material transformation and other technical improvement measures,the pressure difference of the dust collector is stable at≤1 500Pa,the dust emission concentration is≤10mg/Nm3,the dust collector is stable and efficient,and it also meets the requirements of ultra-low emission.

Abstract:Driven by the advancement of the"dual-carbon"goals and the demand for high-performance concrete in the construction industry,the green and refined development of high-quality sand and gravel aggregate production has become the focus of attention in the industry.Traditional aggregate production lines have problems such as high energy consumption,poor particle shape,and severe pollution,making it difficult to meet modern engineering requirements for aggregate gradation stability and low-carbon production.Taking a high-quality sand and gravel aggregate project with an annual output of 3 million tons as an example,this paper elaborates on the technical schemes of the project,including plant layout,process flow,main equipment,particle gradation,product performance,environmental protection control,and intelligent application.The project adopts a two-stage impact crushing process to produce three types of high-quality aggregates and one type of ordinary manufactured sand.The entire process uses closed conveying via belt conveyors and elevators,achieving a dust emission of less than 5 mg/Nm³ in the plant area.Additionally,the aggregates have good particle shape,excellent gradation,and little surface dust adhesion.By implementing a vertical roller mill system for sand making,the project addresses the quality control problems of traditional sand making processes.This system features high production capacity,low power consumption,and the product sphericity reaches over 0.82.The vertical mill sand making process shows high development potential.