Abstract: Aiming at the practical problems of frequent coating and delayed blockage prediction of preheaters when co-processing high-sulfur alternative fuels in cement clinker production, based on the full-process digital platform of a 5 000t/d cement production line, an intelligent early warning system for preheater coat formation was developed.By integrating multi-source data from raw materials, fuel, calcination process, and quality inspection, and combining infrared thermal imaging for full-area temperature measurement with quantitative modeling methods, the system establishes a "comprehensive coating index" model for the preheater to uniformly quantify the overall coating degree and its evolution trend, enabling real-time root-cause analysis of key factors triggering coating. Engineering application results show that the system can achieve early prediction of coating risks and quantitative forecasting of coating thickness. Since its implementation, under conditions of using 3.7×104t of high-sulfur carbon black as alternative fuel, no preheater shutdowns due to coating-induced blockage have occurred. In addition, the measured temperature data provides data support for refined health management of refractory linings. This system possesses great promotion value for coating risk control when cement plants co-process alternative fuels containing sulfur, chlorine, alkali and other harmful components.
李亮. 水泥生产线预热器结皮智能预警系统构建及工程实践应用[J]. 水泥技术, 2026, 1(5): 83-88.
Li Liang. Construction and Engineering Application Practice of Intelligent Early Warning System for Scaling in Preheaters in Cement Plants. Cement Technology, 2026, 1(5): 83-88.
