Energy conservation, consumption reduction and production capacity improvement renovation (overall plan) - Services and Solutions - Nanjing JianAn Industrial Group Co., Ltd.

Confronted with the "carbon peaking and carbon neutrality" policy constraints and growing industry competition, cement production lines are in urgent need of systematic renovation to meet the three key objectives of energy consumption reduction, production capacity improvement and environmental compliance. Focusing on the key links of the entire cement production process, this project adopts a combined plan of "equipment upgrading + process optimization + intelligent management and control" to help enterprises reduce comprehensive energy consumption by 10%-30%, increase clinker production capacity by 10%-30%, meet the latest environmental emission standards, and promote green and low-carbon transformation. Customized solutions for each enterprise: Based on the existing equipment of cement plants, regional resources (such as sources of biomass and industrial hazardous waste) and policy requirements, provide "plant-specific" renovation solutions.

Full-lifecycle service

Design, equipment procurement, construction and installation, commissioning and training, as well as post-operation maintenance are covered, ensuring stable operation up to standards after renovation.

Core renovation fields and key projects:

Firing system renovation:

No.	Key Points for Consumption Reduction	Technical Measures	Expected Reduction in Comprehensive Coal Consumption
1	Control fuel combustion	Increase the calciner's volume Optimize the ways of feeding air, materials and coal into the furnace Optimize the fuel combustion control in the kiln	Decrease by 0.8–1.2 kg/t.d
2	Improve the thermal efficiency of the preheater, i.e., enhance the heat transfer from materials in the Cn-1 cyclone	Improve the separation efficiency of the cyclone Strengthen gas-solid heat transfer Appropriately control the outlet temperature of the calciner at a relatively low level	Decrease by 1–2 kg/t.d
2		Transform the five-stage preheater into a six-stage one	Decrease by 3–4 kg/t.d
3	Improve the thermal efficiency of the grate cooler	Control air leakage in the system Control the coal feeding air volume and primary air volume	Decrease by 0.2 kg/t.dl
4	Control the cold air entering the system	Replace with the 4th-generation grate cooler Optimize the front-end air distribution Optimize the air extraction position for AQC furnace	Decrease by 0.5 kg/t.d
5	Reduce heat dissipation from equipment surfaces	Use heat-insulating materials and kiln bricks with low thermal conductivity Apply external thermal insulation to the connecting pipes of C1 and C2	Decrease by 1.5–2.5 kg/t.d
6	Improve the burnability of raw meal and reduce the heat required for clinker formation	Optimize the mixing scheme	Decrease by 1.5 kg/t.d
7	Introduce air and material preheating technology into the system	Make use of waste heat for increasing the temperature of primary air and raw meal fed into the kiln	Determine based on actual conditions
8	Reduce the back-mixing degree of solid materials in the system	Replace with a low-resistance smoke chamber	Determine based on actual conditions

To reduce the energy consumption of the firing system, it is first necessary to strengthen the control of raw meal and pulverized coal fed into the system. For the firing system itself, the level of energy consumption mainly depends on the mixing of various media inside the system and the processes of "three transfers and one reaction" (mass transfer, heat transfer, momentum transfer, and chemical reaction). The most direct and effective method is to optimize and control fuel combustion, and to enhance the mixing and separation of gas-solid two-phase flow in the system. On the basis of ensuring the effectiveness of the above processes, measures such as appropriately extending the residence time of solid materials, reducing the back-mixing degree of solid materials in the system, and increasing the turbulence intensity of gas should be adopted to improve the system's adaptability to raw materials and fuels, as well as the control range of operating parameters.