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The drying process of the 2,500-ton clinker production line at Nissan's rotary kiln factory in Shandong Dezhou Dam Co., Ltd., which began operations in August 2003, was responsible for drying slag from two grinding mills. After running for two years, the system underwent multiple maintenance sessions and generally met normal production requirements. However, in October 2005, following the trial operation of the second cement grinding line, the drying capacity became insufficient to meet production demands. This led to serious issues with the boiling furnace, including damage, low thermal efficiency, and difficulties in maintaining stable production and operational rates. These problems also posed significant safety risks, ultimately limiting cement production.
1. Existing Problems
At the top of the boiling furnace, refractory bricks had fallen off, and upper sections had collapsed. Embedded flanges were burned out, and the furnace door had also suffered damage, resulting in brick detachment. The fire-blocking performance was poor, and material burning occurred at the feed inlet, creating a major safety hazard.
2. Technological Transformation Measures
To extend the service life of the western wall of the boiling furnace, its thickness was increased from 750mm to 1050mm. A new steel structure was added beneath the wall to enhance strength and load-bearing capacity. The upper part of the flange was prefabricated to improve structural support, protect the embedded flanges, and increase thermal efficiency. Additionally, the thickness of the embedded flange’s steel plate was increased from 8mm to 20mm.
The inlet and flange of the dryer were replaced. The flange width was extended from 710mm to 1050mm, and the inner part of the flange was fully constructed to increase load capacity and protect the dryer barrel, reducing pressure on the embedded flange and extending its lifespan.
The boiling furnace door and lower coal pipe were replaced. A broom was installed on the upper part of the door, and a steel structure was added to reinforce it. Two slag sluices were installed, and an ash churn was added near the embedded flange. This helped reduce wear on the dryer barrel and ensured timely discharge from both chambers.
The dryer inlet chute was replaced and moved westward to reduce the angle of entry, shortening the chute length and preventing direct flame exposure, thereby extending the equipment’s service life.
The smoothness of the cutting chute directly affects the dryer’s output. The connection method was changed from flanged to bolted, increasing the diameter of the blanking lap and thickening the steel plate from 8mm to 16mm. The chute size was upgraded from 300mm×400mm to 500mm×450mm, significantly improving the feeding chute’s durability and solving the issue of frequent blockage. This upgrade greatly enhanced the station’s output and improved material flow.
3. Results of the Transformation
After nearly three months of operation following the upgrades, the dryer’s continuous operation rate improved, and the production capacity at the station increased from 40 tons to 60 tons. This ensured sufficient slag drying for cement grinding and marked a successful transformation.