建材企业转型升级之路—太阳能与窑炉余热综合利用 污泥干化制砖技术 闫广播、孙红波、李连盟、李科、王安星、王光磊 （山东福航新能源环保股份有限公司）

建材企业转型升级之路—太阳能与窑炉余热综合利用

污泥干化制砖技术

闫广播、孙红波、李连盟、李科、王安星、王光磊

（山东福航新能源环保股份有限公司）

摘  要：当前窑炉制砖工艺仍以传统的黏土配料烧制为主，主流工艺为：将黏土、粉煤灰、页岩等按一定比例添加后，通过破碎系统破碎呈粉末状，将水按比例添加搅拌均匀后进行陈化，陈化好的原料送入制砖机进行压制成型，经自动码垛后进入窑炉烧制成品。此生产过程需消耗大量资源及能源，成品烧制需煤粉燃烧产生大量高温烟气进行焙烧，为保证成品砖质量窑炉内烟气降低到一定温度后需引出窑炉，引出窑炉后的高温烟气温度约300℃，为保证厂区尾气处理系统的安全及使用寿命，烟气需要冷却塔降温至约100℃，再进入尾气处理系统，这样大量热量被白白浪费掉。  

为充分利用能源，节约生产成本，在具备窑炉高温烟气可接入的建材厂区，采用太阳能与窑炉余热综合利用对厂区所在地的市政或生活污泥进行集中干化处理，干化后的污泥含水率大大降低，可作为制砖原材料进行资源化利用，该技术是在当前太阳能污泥干化的基础上，通过开发窑炉余热热能共同加速污泥内水分的蒸发；该工艺符合国家节能减排的政策，在减少能源浪费的同时，还能实现资源的更大价值的利用，满足可持续发展要求，对建设地起到良好的环境效益；该技术工艺以运行成本低、操作简单、污泥含水率低、维护保养容易等特点，得到市场的广泛认可。

关键词：窑炉余热；太阳能；污泥干化；制砖原材料；成品砖；

1、概述

1.1技术介绍

太阳能与窑炉余热综合利用污泥干化制砖技术是以太阳能与窑炉余热为热源，对建设地的市政或生活污泥进行低温干化。同时借助太阳能温室保温除湿技术，结合自动化远程控制技术，实现对污泥的干化处理，干化后的污泥含水率大大降低，进行粉碎后按一定比例添加作为制砖原材料，循环后的烟气温度降低至100℃以下，可直接进入尾气处理系统处理后达标排放，干化过程中车间内产生的臭气经管道集中收集后送入生物除臭装置内处理达标排放，除臭产生的废水可回流作为制砖用水，整个过程采用远程自动化控制，无需人员进入现场操作，避免职业病的发生，实现污泥干化与制砖生产的闭环循环。

1.2技术优势

与传统的污泥干化处理工艺相比，其主要优点是：

1、系统利用窑炉余热为主要热源对污泥进行干化，以废制废，属国内首创；

2、系统可解决周边市政、企业等一般固废处理需求，有效改善生态环境；

3、系统运营成本低，污泥处理成本仅为10-30元/吨，经济效益显著；

4、系统自动化程度高、操作简单，安全稳定使用寿命长；

5、系统配有除臭设施，干化后的气体集中处理，达标排放，无二次污染；

6、系统可实现对干化污泥建材利用，实现了污泥的资源化处置；

7、项目利用清洁能源与工业余热为热源降低污泥含水率，同时利用污泥中的热值做为助燃制砖，符合国家相应节能减排政策，满足可持续发展的要求；

2、工艺系统组成及原理分析

2.1工艺系统组成

1、湿污泥输送系统

2、太阳能干化温室系统

3、窑炉余热循环供热系统

4、全自动翻抛布料系统

5、干料收集输送系统

6、原料粉碎、配料成型系统

7、窑炉焙烧系统

8、尾气及臭气处理系统

9、自动化远程控制系统

2.2工艺原理分析说明

湿污泥（含水率60%-80%）经湿泥输送系统设备送入太阳能干化温室，经全自动摊铺布料系统进行自动下料、自动布料、翻抛、平移，并在太阳辐射能及底部窑炉余热平台的作用下水份不断蒸发，污泥含水率降至约30%后经干料输送设备送入原料陈化车间进行陈化。陈化好的干污泥与页岩等配料混合后进行粉碎制砖，砖坯进入窑炉高温焙烧成品砖，制砖过程中持续产生的高温余热则通过风机引出进入散热平台对污泥进行烘干，循环后的烟气温度降低到100℃左右，经引风机送入厂区末端尾气处理系统进行处理达标排放，干化过程中车间内产生的少量臭气经过收集管道集中收集后送入除臭虑塔进行处理，经过滤、喷淋水洗、生物分解等一系列处理将臭气分子进行降解为二氧化碳、水等无害物质，实现气体达标排放，生产过程中产生的废水可循环用于制砖生产用水，真正实现废弃物的资源化利用，产生巨大的经济效益和环境效益。

3、生产工艺流程

3.1工艺流程图

太阳能与窑炉余热综合利用污泥干化制砖工艺流程图

3.2工艺流程说明

外运湿污泥→湿污泥输送系统→太阳能温室及钢板干化平台系统→全自动摊铺布料机系统→干料收集系统→原料粉碎、配料、成型系统→窑炉焙烧系统→成品砖。

（1）湿污泥输送部分可由湿污泥料仓及污泥输送皮带系统组成，污泥通过螺旋输送机、斜皮带机、布料皮带输送机和犁式卸料器将污泥均匀输送至各摊铺布料机的中转料仓，皮带机污泥输送具有操作简单，效率高的优点，也可采用污泥柱塞泵输送，此方式封闭性好适用于含水率高的污泥输送。                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                             

（2）太阳能温室系统由温室主体、冷凝水收集、顶通风系统组成。温室为四顶尖主动式太阳能温室，主骨架、各构件及连接件均为热镀锌材料，顶部及四周覆盖中空阳光板，透光率≥80%，可有效吸收太阳辐射能并持续保温，顶通风为顶部设有天窗用于除湿换气，该干化车间保温除湿效果明显，为污泥干化提供能量。

（3）全自动摊铺布料机系统由螺旋下料机、刮板平移换向系统、物料翻抛系统、湿料强通风系统组成，其原理是通过螺旋喂料机控制物料均匀下料，通过刮板使物料逐渐向一侧移动，将物料均匀得摊铺到干化平台上；通过翻抛系统不断翻新物料上表面，湿料强通风系统增大污泥表面的空气流动，从而不断提高湿物料干化速度。

（4）余热散热平台部分由余热输送管路、引风机、钢板散热平台组成。高温余热经引风机通过输送管路定量输送至钢板散热平台底部的循环烟道，高温余热呈迂回状缓慢通过烟道，通过热传导为平台上方摊铺的污泥干化提供能量，增加水分蒸发速率，干化平台由钢板铺设而成，钢板传热系数高，效率高，使得污泥获得更均匀的热量，从而加速水分的蒸发。

（5）干料收集输送系统是由室内干料收集皮带机、干料集中收集皮带机和干料输送斜皮带机组成，将处理后的污泥集中收集输送至陈化车间内存放。

（6）原料粉碎、配料、成型系统是由粉碎机、配料机、制砖机组成，干化后的污泥含水率大大降低，性质稳定，经粉碎机粉碎后与制砖原材料按10%-20%的比例进行配料，最后进入制砖机压制成品砖。

（7）成品砖经码垛后进入窑炉焙烧系统高温烧制成品砖，期间持续产生高温余热进入干化车间底部干化平台内进行闭环循环，循环后的余热温度降低可直接进入窑炉尾气处理系统处理达标排放，干化过程中车间内产生的气体经管道集中收集送入配套生物除臭系统内处理达标排放。

（8）自动化远程控制系统实现了集中控制方式，操作人员可通过现场监控摄像头实时掌握现场情况，实现一人操控即可实现污泥上料-摊铺干化—干料收料—粉碎、配料、成型-窑炉焙烧整个污泥污泥处理过程，降低干化生产人力投入。

4、工程案例

江苏某太阳能与窑炉余热综合利用污泥干化制砖项目

本项目建设在制砖企业生产厂区内，可用高温烟气量约120000m³/h，温度200-250℃左右，日处理200吨市政污泥，含水率由65%降至40%，干化后的污泥量为84t，按10%-20%的添加比例计算可日生产成品砖约12万块，日节约黏土、粉煤灰、页岩等原材料成本约15000元，经济效益可观，同时解决了当地污泥处理难题，为当地环境质量提升做出贡献，得到当地政府的关注，成为当地的标杆企业。

                             尾气处理

       湿污泥上料           温室增温及钢板地面加热       摊铺翻抛及收料                            

干污泥输送     

成品砖                   窑炉焙烧制砖                    与黏土、煤灰、配料成型

污泥干化制砖生产工艺流程