Application of Spray Cooling System at the Kiln Head

The transformation of the kiln head electric dust collector into a bag filter has been widely applied. To meet the temperature requirements of the filter after the transformation, the tray cooler needs to be increased.Spray cooling.system. Combined with the relevant issues encountered in engineering examples, suggestions and summaries are made on the previous phase of service, system control optimization, selection of installation locations, and usage maintenance. This article introduces the types and control methods of spray systems commonly used at the cement kiln head. Now, let's learn about the application of the spray cooling system at the kiln head!

1. The role of installing a spray cooling system.

In recent years, due to increasingly strict national dust emission standards, after the "electric to bag" transformation at the kiln head, the normal operating temperature of the filter material is lower compared to the vacuum cleaner. Therefore, it is necessary to effectively control the supply air temperature of the cooler to prevent the filter bags from being damaged at high temperatures. In the past, methods to reduce the temperature at the cement kiln head commonly included mixing in cold air, humidifying pipelines, increasing multi-tube coolers, and setting up heat discharge boilers. Installing cold air valves in the pipelines can introduce a large amount of cold air, achieving rapid cooling within a certain temperature range. The transformation of electric dust collectors to bag dust collectors in domestic cement production lines has been implemented extensively. However, as the temperature decreases, the cooling efficiency also decreases, and introducing a large amount of cold air can lead to excessive load on the dust removal system, resulting in a series of adverse effects.

2. Characteristics of the spray cooling system at the cement kiln head.

　　Spray cooling.Function and mechanism of the system.

The basic function of the spray cooling system at the cement kiln head is to pressurize through multi-stage pumps, delivering water to the nozzles via outlet pipelines. When the temperature signal from the temperature sensor exceeds the set value, the system automatically starts. The cooling water is filtered through a filter from the water source tank, and the fine water mist particles generated mix rapidly with the high-temperature flue gas.

Types of general spray cooling systems.

The spray cooling systems used at the cement kiln head are generally divided into two main categories: single fluid and dual fluid. In this method, the pressure at the nozzle is relatively high, with the working pressure of different nozzle types usually between 0.6 and 1.2 MPa, and the pump power is around 15 kW. The single fluid mainly pressurizes the injected water flow through a high-pressure water pump, achieving atomization through the mechanical characteristics of the nozzle. It has the advantages of simple structure, low air consumption, and relatively low investment cost. The dual fluid refers to the fact that in addition to water, a certain pressure of compressed air is also required. High-pressure gas and liquid mix directly inside the nozzle, achieving atomization by cutting the liquid with gas under high-pressure injection conditions.

General.Spray cooling.System control.

Considering the usage frequency and investment cost, generally, foreign spray companies (such as the American spray) mostly use a 6-port wide-angle head equipped with 6 nozzles for each spray gun. For cement kiln heads below 6000t/d, 2 to 3 spray guns are generally used. This mode with fewer spray guns remains in a spraying state during operation. The cement kiln head mostly adopts a single fluid spray cooling system, with the number of spray guns equipped within different air volumes and cooling ranges determined by the type of nozzle used and the required injection flow rate. The main adjustment of flow is controlled by a variable frequency drive that controls the pump speed, maintaining the continuity of temperature changes.

3. Issues to pay attention to.

Currently, the level of in-depth research and engineering application of spray systems at the cement kiln head in China is insufficient, leading to frequent production issues during actual use. This discusses several problems encountered in actual production and areas that need improvement.

Preliminary service is very important.

Preliminary service refers to confirming the situation of the water source and gas source, understanding the configuration of cold air valves on the pipeline, and the design of convenient maintenance locations, etc. Technical personnel should understand the actual situation on-site before design. Determine the installation location of the water tank and pump unit, measure the dimensions of the cooler, the positions of each air outlet, and the diameter and length of the main pipeline at the tail of the cooler.

The above introduces the application of the spray cooling system at the kiln head. If you need to know more, feel free to contact us!