Abstract
The invention relates to multi-stage cement calcining plant suspension preheater of the kind mentioned in the introduction, wherein the preheater comprises a top separator comprising a central tube entering the top separator in a lowermost part of the separator housing whereas the central tubes of the bottom separators enters the separator housing in an upper part of the separator housing.
Claims
1. A multi-stage cement calcining plant suspension preheater comprising: a plurality of stages each of which has a separator for separating raw cement meal from a gas in which the meal is suspended and wherein the separators of the plurality of stages are serially connected and in series with a calcining combustor, the plurality of stages comprising a top separator arranged at the uppermost stage of the preheater and a plurality of bottom separators arranged at the lowermost stages of the preheater, the top separator comprising: a top separator housing comprising a substantially cylindrical top separator upper part and a substantially conical top separator lower part, a top separator tangential inlet in the top separator upper part of the top separator housing for introducing an un-separated stream of gas and raw cement meal in suspension, a top separator outlet in a lowermost end of the conical top separator lower part for discharging a first fraction of coarse cement raw meal material, a top separator central tube extending with a free end axially into the top separator housing for diverting a second fraction of fine cement raw meal material and gas, the bottom separators comprising: a bottom separator housing comprising a substantially cylindrical bottom separator upper part and a substantially conical bottom separator lower part, a bottom separator tangential inlet in the bottom separator upper part of the bottom separator housing for introducing an unseparated stream of gas and raw cement meal in suspension, a bottom separator outlet in a lowermost end of the conical bottom separator lower part for discharging a first fraction of coarse cement raw meal material, a bottom separator central tube extending with a free end axially into the bottom separator housing for diverting a second fraction of fine cement raw meal material and gas, wherein the top separator central tube enters the top separator housing in the lower part of the top separator housing, and wherein the central tubes of the bottom separators enter the bottom separator housing in the upper part of the bottom separator housing.
2. The preheater of claim 1, wherein the top separator comprises a top separator suspension having a receiving opening for receiving and supporting the top separator, wherein a receiving opening diameter of the receiving opening is smaller than a top separator upper part diameter of the top separator upper part and wherein the top separator is suspended by the top separator suspension engaging the top separator lower part.
3. The preheater of claim 1, wherein a ratio between an upper part diameter D.sub.CYL of the top separator upper part and a central tube diameter D.sub.CT of the top separator central tube is between 1.8<D.sub.CYL/D.sub.CT<3.
4. The preheater of claim 3, wherein the upper part diameter of the top separator upper part is larger than a upper part diameter of the bottom separator upper part.
5. The preheater of claim 1, wherein the top separator comprises a material feed inlet arranged in a central part of the upper part of the top separator housing.
6. The preheater of claim 5, wherein the material feed inlet is arranged co-axially with a longitudinal center axis of the top separator housing.
7. The preheater of claim 5, wherein the material feed inlet comprises means for spreading material feed in a tangential direction of the top separator housing directing the material feed in a direction from the material feed inlet towards the periphery of the top separator housing such that the material feed exiting the material inlet has a tangential velocity component in a tangential direction of the top separator housing.
8. The preheater of claim 7, wherein, the tangential direction is co-current with a direction of airflow in the top separator.
9. The preheater of claim 5, wherein the material feed inlet comprises means for spreading material feed in a radial direction of the top separator housing directing the material feed in a direction from the material feed inlet towards the periphery of the top separator housing such that the material feed exiting the material inlet has a radial velocity component in a radial direction of the top separator housing.
10. The preheater according to claim 7, wherein the means for spreading the material feed in the tangential direction comprises an exit tube directed in the tangential direction.
11. The preheater according to claim 7, wherein the means for spreading the material feed in the tangential direction comprises a splash plate angled in the tangential direction.
12. The preheater according to claim 7, wherein the means for spreading the material feed in the tangential direction comprises material accelerating means such as pressurized air or mechanical conveyor means.
13. The preheater according to claim 7, wherein the means for spreading the material feed in the tangential direction comprises a rotating plate for accelerating the material after entry into the top separator.
14. The preheater of claim 13, wherein the rotating plate comprises one or more substantially vertical shovel blades for forcing the material in the direction of rotation of the rotating plate.
15. The preheater of claim 14, wherein the shovel blades extend from the center of the rotating plate to the periphery of the rotating plate in a substantially radial direction.
16. The preheater of claim 14, wherein the shovel blades are gradually decreasing in height from the center of the rotating plate towards the periphery of the rotating plate.
17. The preheater according to claim 9, wherein the means for spreading the material feed in the radial direction comprises an exit tube directed in the radial direction.
18. The preheater according to claim 9, wherein the means for spreading the material feed in the radial direction comprises a splash plate angled in the radial direction.
19. The preheater according to claim 9, wherein the means for spreading the material feed in the radial direction comprises material accelerating means such as pressurized air or mechanical conveyor means.
20. The preheater according to claim 9, wherein the means for spreading the material feed in the radial direction comprises a rotating plate for accelerating the material after entry into the top separator.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention and its many advantages will be described in more detail below with reference to the accompanying schematic drawings, which for the purpose of illustration show some non-limiting embodiments and in which
(2) FIG. 1 shows a cross-sectional view of a multi-stage cement calcining plant suspension preheater of the prior art;
(3) FIG. 2 shows a cross-sectional view of a multi-stage cement calcining plant suspension preheater of the invention;
(4) FIG. 3 shows a magnified view of a top separator of a multi-stage cement calcining plant suspension preheater of the prior art;
(5) FIG. 4 shows a magnified view of a top separator of a multi-stage cement calcining plant suspension preheater of the invention.
(6) FIG. 5 shows a cross-sectional view of a multi-stage cement calcining plant suspension preheater of the invention;
(7) FIG. 6a shows a cross-sectional view of a multi-stage cement calcining plant suspension preheater of the invention;
(8) FIG. 6b shows a magnified view of an embodiment of a material feed inlet of a top separator of a multi-stage cement calcining plant suspension preheater of the invention;
(9) FIG. 7 shows a cross-sectional view of an embodiment of a material feed inlet of a top separator of a multi-stage cement calcining plant suspension preheater of the invention;
(10) FIGS. 8a-d show four different embodiments of a rotating plate of the invention;
(11) FIG. 9a shows a cross-sectional view of a top cyclone of the invention with airflow and material flow patterns;
(12) FIG. 9b shows a cross-sectional view of a top cyclone of the invention with airflow and material flow patterns;
(13) FIGS. 10a-c show four different arrangements of means for spreading the material feed in a cyclone;
(14) FIG. 11a shows a perspective view of an embodiment of the means for spreading the material feed in a cyclone comprising two tubes;
(15) FIG. 11b shows a cross-sectional view of an embodiment of the means for spreading the material feed in a cyclone comprising two tubes;
(16) FIG. 11c shows a perspective view of an embodiment of the means for spreading the material feed in a cyclone comprising three tubes;
(17) FIG. 11d shows a perspective view of an embodiment of a top cyclone comprising means for spreading the material feed comprising two tubes and means for accelerating the material feed by introducing pressurised air through a valve;
(18) FIG. 12 shows a cross-sectional perspective view with flow patterns of an embodiment of a top cyclone comprising the means for spreading the material feed comprising two tubes and means for accelerating the material feed by introducing pressurised air through a valve;
(19) FIG. 13a shows a perspective view of an embodiment of a means for spreading the material feed comprising two tubes angled in a radial and tangential direction for introducing the material feed in the cyclone with a radial and tangential velocity component;
(20) FIG. 13b shows a perspective view of an embodiment of a means for spreading the material feed comprising one tube and a splash plate angled in a radial and tangential direction for introducing the material feed in the cyclone with a radial and tangential velocity component; and
(21) FIG. 14 shows a cross-sectional perspective view of a top cycle with flow restriction means on the outlet of a top cyclone.
(22) All the figures are highly schematic and not necessarily to scale, and they show only those parts which are necessary in order to elucidate the invention, other parts being omitted or merely suggested.
DETAILED DESCRIPTION OF THE INVENTION
(23) FIG. 1 shows a cross-sectional view of a multi-stage cement calcining plant suspension preheater 1 of the prior art comprising a plurality of stages each of which has a separator for separating raw cement meal from a gas in which the meal is suspended and wherein said separators of said plurality of stages are serially connected and in series with a calcining combustor 4, where the plurality of stages comprises a top separator 2 arranged at the uppermost stage of the preheater and a plurality of bottom separators 3 arranged at the lowermost stages of the preheater. FIG. 2 shows a cross-sectional view of a multi-stage cement calcining plant suspension preheater of the invention also comprising a plurality of stages each of which has a separator for separating raw cement meal from a gas in which the meal is suspended and wherein said separators of said plurality of stages are serially connected and in series with a calcining combustor 4, where the plurality of stages comprises a top separator 2 arranged at the uppermost stage of the preheater and a plurality of bottom separators 3 arranged at the lowermost stages of the preheater. As becomes evident from the difference between the prior art preheater shown in FIG. 1 and the preheater of the invention shown in FIG. 2, the height H1 of the tubing 13 leading to the top separator 2 of the prior art is much higher than the height H2 of the tubing 13 leading to the top separator 2 of the invention and thus construction costs are significantly limited. FIG. 3 is a magnified view of the top separator of the preheater of the prior art as shown in FIG. 1. As seen in FIG. 3 the top separator of the preheater of the prior art comprises a central tube 9 of the top separator which enters the separator housing in the upper part 10 of the separator housing 5, like the central tubes of the bottom separators enters the separator housing in the upper part of the separator housing as shown in FIG. 1. The separators 2, 3 comprise a separator housing 5 comprising a substantially cylindrical upper part 6 and a substantially conical lower part 7, a tangential inlet 8 in an upper part 10 of the separator housing 5 for introducing an un-separated stream of gas and raw cement meal in suspension. Further the top separator of the prior art comprises an outlet 15 in a lowermost end 14 of the conical part 7 for discharging a first fraction of coarse cement raw meal material, and a central tube 9 extending with a free end axially into the separator housing 5 for diverting a second fraction of fine cement raw meal material and gas. The central tube 9 of the top separator 2 enters the separator housing in the upper part 10 of the separator housing 5. Furthermore, the top separator 2 comprises a top separator suspension having a receiving opening 17 for receiving and supporting the top separator 2. As seen by the hatched area the top separator of the prior art has a worst case scenario filling 18 extending up till the tangential inlet 8. If the outlet 15 is clogged during operation the top separator may be filled until the raw meal finally can escape the separator through the central tube 9. The weight of a completely filled separator with this degree of filling is very substantial and the civil construction must be dimensioned to be able to accommodate this weight. FIG. 4 shows a magnified view of the top separator according to the invention where the central tube 9 enters the separator housing 5 through a lower part 7 of the separator housing 5 and not through the upper part 10 as opposed to the prior art solution as seen in FIG. 1. It is essential that the central tube 9 does not enter the separator housing 5 through the upper part 10 in order to achieve the invention. The invention has several advantages over the prior art, the main advantage being the lowered worst case scenario degree of filling of the top separator 2 which allows a decrease in the costs of constructing the civil building. Since the raw meal would be able to escape the separator through the central tube 9 if the outlet 15 is clogged, the weight of the completely filled top separator 2 would be much lower in a preheater according to the invention. Furthermore this has the advantage that old top separators could be interchanged in existing preheaters with larger top separators without enforcing the civil construction further. The construction has been dimensioned according to the old type of top separators and the new type will have a lower worst case scenario filling weight, thus it is possible to install a larger separator using the existing construction. As seen in FIG. 4 even the existing suspension of the old top separator may be re-used since the new top separator having a larger diameter D.sub.cyl of the cylindrical part 6 may be supported in the existing suspension 16, since the separator may be supported on the conical part 7 of the separator.
(24) Preferably the ratio between an upper part diameter D.sub.CYL of the substantially cylindrical upper part 6 of the separator housing 5 and a top separator central tube diameter D.sub.CT is between 1.8<D.sub.CYL/D.sub.CT<3 or more preferably 2.1<D.sub.CYL/D.sub.CT<2.8 or even more preferably 2.3<D.sub.CYL/D.sub.CT<2.6.
(25) The relation between the central tube diameter D.sub.CT and cylindrical upper part diameter D.sub.CYL makes it possible to obtain a fractional separation efficiency in a range between 91% to 95% which is the preferred range when the resulting pressure drop through the separator typically lies in a range between 5-20 mBar. The top separator upper part diameter of the cylindrical upper part of the top separator housing is larger than a bottom separator upper part diameter of the upper part of the bottom separator housings of the bottom separators.
(26) As seen in FIG. 4 a new top separator may be fitted into an existing receiving opening 17 of the suspension 16 by supporting the housing on the conical part of the housing and thereby a new separator having a larger diameter D.sub.CYL of the cylindrical part 6 in the new top separator 2 than in the old top separator 2 without changing the suspension design of the suspension 16 or the diameter D.sub.RO of the receiving opening 17.
(27) FIG. 5 shows a cross-sectional view of a multi-stage cement calcining plant suspension preheater 1 of the invention comprising a plurality of stages each of which has a separator for separating raw cement meal from a gas in which the meal is suspended and wherein said separators of said plurality of stages are serially connected and in series with a calcining combustor 4, where the plurality of stages comprises a top separator 2 arranged at the uppermost stage of the preheater and a plurality of bottom separators 3 arranged at the lowermost stages of the preheater wherein the top separator 2 comprises a material feed inlet 35 arranged in a central part 36 of the upper part of the top separator housing 10.
(28) FIG. 6a shows a cross-sectional view of a multi-stage cement calcining plant suspension preheater of the invention wherein the material feed inlet 35 comprises means for spreading the material feed 38 in a tangential and or radial direction.
(29) FIG. 6b shows a magnified view of an embodiment of a material feed inlet comprising means for spreading the material feed 38 in a tangential and or radial direction in a tangential direction.
(30) FIG. 7 shows a cross-sectional view of the same embodiment as in FIG. 6b, where the material feed inlet 35 comprises means for spreading the material feed 38 having an rotation axle 39 driven by a motor 40 and a material feed duct 41 for spilling the material feed onto a rotating plate 12 with shovel blades 43.
(31) FIGS. 8a-d show four different embodiments of a rotating plate 12 with shovel blades 43 driven by a rotation axle.
(32) FIG. 9a shows a cross-sectional view of a top cyclone of the invention with airflow and material flow patterns. As shown in FIG. 9a the top separator 44 comprises a tangential inlet 22 in the upper part of the separator housing, a top separator central tube 15 entering the separator housing 46 in the lower part 17 of the top separator housing 46, and wherein the top separator 44 comprises a material feed inlet 35 arranged in a central part 48 of an upper part 49 of the top separator housing 46. The material exits the top separator 44 through an outlet in a lowermost end 21 of the conical lower part 20. As illustrated the airflow enters the cyclone in the periphery of the upper part 19 of the top separator and exits the cyclone through the central tube extending with a free end axially into the separator housing in the substantially conical lower part 20 of the top separator, whereas the flow pattern of the material feed according to the invention enters the top separator from the centrally arranged material feed inlet 35 and is directed towards the periphery of the separator by centrifugal forces. Therefore the air and material is mixed in counter-current flow increasing the heat exchange significantly. To adjust the speed and direction of the material feed the material feed inlet 35 may comprise means for spreading the material feed 38 in a tangential and/or radial direction of the separator housing 46 of the top separator 44 directing the material feed in a direction from the centrally arranged inlet towards the periphery of the housing of the top separator 44. The means for spreading the material feed 38 in FIG. 9a comprises two tubes 23 connected to a material feed container 24 and further connected to a valve 49 for allowing pressurized air to enter the tubes 23 and speed up the material entering the top separator 44.
(33) In FIG. 9b the means for spreading the material feed 38 comprises a rotation axle 39 driven and a material feed duct 41 for spilling the material feed onto a rotating plate 12 with shovel blades 43 shows a cross-sectional view of a top cyclone of the invention with airflow and material flow patterns. As illustrated also in FIG. 9b the airflow enters the cyclone in the periphery of the upper part 19 of the top separator and exits the cyclone through the central tube extending with a free end axially into the separator housing in the substantially conical lower part 20 of the top separator, whereas the flow pattern of the material feed according to the invention enters the top separator from the centrally arranged material feed inlet 35 and is directed towards the periphery of the separator by centrifugal forces. Therefore the air and material is mixed in counter-current flow increasing the heat exchange significantly. To adjust the speed and direction of the material feed the material feed inlet 35 may comprise means for spreading the material feed 38 in a tangential and/or radial direction of the separator housing 46 of the top separator 14 directing the material feed in a direction from the centrally arranged inlet towards the periphery of the housing of the top separator 44.
(34) FIGS. 10a-c show three different arrangements of means for spreading the material feed 38 in a separator. FIG. 10a shows the means for spreading the material feed 38 arranged partially outside a central part 26 of the separator housing 46. This is unwanted since it will create an inhomogeneous distribution of material in the separator. As shown in FIG. 10b, the means for spreading the material feed 38 must be arranged in a central part of the separator housing to provide a homogeneous distribution of the material in the separator housing the material feed inlet 35 is to be placed in a central part. If the airstream entering the separator housing 46 through the tangential inlet 22 forces the material towards the periphery of the separator housing 46 too quickly to provide optimal heat exchange, an inlet zone 27 between the means for spreading the material feed 38 and the tangential inlet 22 may comprise an inlet shield 28. Placing an inlet shield 28 in the inlet zone 27 is more advantageous than arranging the means for spreading the material feed 38 away from the central part 26 of the separator housing 46. As shown in FIG. 10c the means for spreading the material feed 38 is optimally placed in the central part of the cylindrical part of the separator housing 46.
(35) FIG. 11a shows a perspective view of an embodiment of the means for spreading the material feed 38 in a cyclone comprising two tubes entering the separator housing 46 in the central part of the upper part. FIG. 11b shows a cross-sectional view of an embodiment of the means for spreading the material feed 38 in a cyclone comprising two tubes entering the separator housing 46 in the central part of the upper part. FIG. 11c shows a perspective view of an embodiment of the means for spreading the material feed in a cyclone comprising three tubes entering the separator housing 46 in the central part of the upper part.
(36) FIG. 11d shows a perspective view of an embodiment of a top cyclone comprising means for spreading the material feed 38 comprising two tubes 23 and means for accelerating the material feed by introducing pressurised air through a valve 49 to accelerate material conveyed from a material feed container 24.
(37) FIG. 12 shows a cross-sectional view of a top cyclone of the invention with airflow and material flow patterns. As shown in FIG. 12 the top separator 44 comprises a tangential inlet 22 in the upper part of the separator housing, a top separator central tube 15 entering the separator housing 46 in the lower part 47 of the top separator housing 46, and wherein the top separator 44 comprises a material feed inlet 35 arranged in a central part 48 of an upper part 19 of the top separator housing 46. The material exits the top separator 44 through an outlet in a lowermost end 21 of the conical lower part 20.
(38) As illustrated the airflow enters the cyclone in the periphery of the upper part 19 of the top separator and exits the cyclone through the central tube extending with a free end axially into the separator housing in the substantially conical lower part 20 of the top separator, whereas the flow pattern of the material feed according to the invention enters the top separator from the centrally arranged material feed inlet 35 and is directed towards the periphery of the separator by centrifugal forces. Therefore the air and material is mixed in counter-current flow increasing the heat exchange significantly. To adjust the speed and direction of the material feed the material feed inlet 35 may comprise means for spreading the material feed 38 in a tangential and/or radial direction of the separator housing 46 of the top separator 44 directing the material feed in a direction from the centrally arranged inlet towards the periphery of the housing of the top separator 44. The means for spreading the material feed 38 in FIG. 12 comprises two tubes 23 connected to a material feed container 24 and further connected to a valve 49 for allowing pressurized air to enter the tubes 23 and speed up the material entering the top separator 44.
(39) FIG. 13a shows a perspective view of an embodiment of a means for spreading the material feed comprising two tubes 23 angled in a radial and tangential direction for introducing the material feed in the cyclone with a radial and tangential velocity component. FIG. 13b shows a perspective view of an embodiment of a means for spreading the material feed 8 comprising one tube 23 and a splash plate 29 angled in a radial and tangential direction for introducing the material feed in the cyclone with a radial and tangential velocity component.
(40) FIG. 14 shows a cross-sectional perspective view of a top cycle with flow restriction means 30 on the top separator central tube 45 of a top separator 44.
