In the production process of quartz plate sand, energy consumption is usually
an important cost factor, and the waste heat and exhaust gas generated during
production activities also have a certain impact on the environment. Therefore,
taking effective measures for energy recovery and utilization not only helps to
reduce production costs, but also improves resource utilization efficiency and
reduces environmental pollution. Here are some common energy recovery and
utilization measures in the production process of quartz plate sand:
1. Waste heat recovery and utilization
(1) High temperature exhaust gas recovery
The production process of quartz plate sand usually involves high-temperature
operations such as drying, roasting, etc. These high-temperature exhaust gases
can be recovered through specialized exhaust gas recovery systems, and the heat
in the exhaust gases can be transferred to the production system through heat
exchange devices. For example:
Waste heat boiler: High temperature exhaust gas is recovered through boiler
equipment and used to produce steam or hot water, which can be used for drying
equipment or other heat treatment processes.
Hot air recovery: Using a hot air recovery system, the heat in
high-temperature exhaust gas is transferred through a heat exchanger to
equipment that requires hot air in the production process, such as dryers,
heating furnaces, etc., thereby reducing external energy consumption.
(2) Recovery of waste heat
The drying and roasting processes of quartz sand consume a large amount of
thermal energy, and the waste heat generated can be recovered and reused through
a heat exchange system. Waste heat can be used to heat air, hot water, or other
processes that require thermal energy, reducing reliance on external energy
sources. For example:
Waste heat boiler system: Install a waste heat boiler to heat water or air
through the waste heat in the exhaust gas, which is used for drying, heating and
other processes.
Waste heat pump system: Using heat pump technology, low-grade thermal energy
in exhaust gas is raised to higher temperatures for use in other processes that
require heat in production.
2. Energy recovery and optimization
(1) Variable frequency speed regulation technology
In the production process of quartz plate sand, many equipment such as ball
mills, vibrating screens, fans, etc. require a large amount of electrical
energy. By controlling the operating speed and load of the equipment through a
frequency converter, it is possible to effectively reduce energy consumption,
while avoiding idle operation of the equipment and improving energy utilization
efficiency.
Variable frequency drive (VFD): Used to regulate the speed of equipment,
optimize workload, reduce energy consumption, especially for equipment such as
mills, fans, pumps, etc., it can adjust power output according to actual
production needs.
(2) Waste electrical energy feedback
For some high-power devices (such as electric vibrating screens, electric
hoists, etc.), the energy generated during their operation can be fed back to
the power grid or other equipment through a feedback system, thereby improving
energy utilization efficiency. The feedback system can convert the kinetic
energy generated during device operation into electrical energy and feed it back
to the power grid or storage devices for reuse.
3. Recycling and utilization of water resources
During the production process of quartz sand, especially during wet
processing, a large amount of wastewater is generated. In order to save water
resources and reduce wastewater treatment costs, measures for water resource
recovery and reuse can be taken.
(1) Wastewater recycling
By setting up wastewater recovery tanks, sedimentation tanks, and filtration
systems, the wastewater generated during the production process is recovered and
impurities are removed through filtration, sedimentation, and other treatment
methods, making it reusable in the production process, such as for wet grinding,
cleaning, cooling, etc.
(2) Wastewater treatment and resource utilization
Solid impurities and dissolved substances in wastewater can be treated
through sludge dewatering, sedimentation tanks, and water purification equipment
to remove harmful substances from the wastewater and recycle it back to the
production line for use. At the same time, sediment in wastewater, such as mud
and sand, can be used as building materials or landfill soil to reduce
environmental pollution.
4. Optimize production processes and procedures
(1) Process optimization
By designing production processes and procedures reasonably, we can reduce
the ineffective consumption of energy. For example, optimizing the crushing,
screening, and grinding processes of quartz sand to avoid excessive processing
and reduce electricity consumption.
Reduce material handling and transportation energy consumption: By reasonably
arranging equipment and optimizing the transportation system, the handling and
transportation time of materials in the production line can be reduced, and
energy consumption can be lowered.
(2) Material recycling and reuse
During the production process of quartz plate sand, some production waste may
be generated (such as quartz sand fine powder, slag, etc.), which can be reused
in other links of the production line through a recycling system to reduce waste
generation, lower raw material costs, and reduce energy consumption.
5. Application of solar energy and other renewable energy sources
(1) Solar hot water system
In some processes that require a large amount of hot water (such as washing,
heating, etc.), solar hot water systems can be used instead of traditional
electric heating systems, using solar energy for preheating to reduce external
energy consumption.
(2) Wind and solar power generation
If the production base is located in a suitable geographical location, it may
be considered to install wind turbines or solar panels to convert wind and solar
energy into electrical energy for use in the production process. Especially in
some regions, solar and wind energy are cheap and sustainable clean energy
sources.
6. Waste gas treatment and energy utilization
(1) Thermal energy recovery from exhaust gas
Some high-temperature exhaust gas treatment systems, such as combustion
systems, can recover and convert the thermal energy in the exhaust gas into
usable thermal or electrical energy. This method is particularly suitable for
high-temperature smelting, roasting, and other processes in quartz sand
production.
(2) Flue gas desulfurization and denitrification treatment
Harmful substances in exhaust gas, such as sulfur dioxide and nitrogen
oxides, can be removed through chemical treatment, adsorption, and other methods
to ensure emissions meet environmental standards, reduce pollution, and recycle
certain usable substances. For example, desulfurization waste liquid can be used
in cement production.
7. Intelligent control and monitoring
Real time monitoring and adjustment of energy consumption in quartz sand
production lines using digital and intelligent control systems. These systems
can automatically adjust the operating mode of equipment and optimize energy
utilization based on parameters such as production load, temperature, humidity,
and power consumption. For example:
Energy Management System (EMS): By collecting and analyzing real-time data
from production lines, intelligently adjusting equipment operation, and reducing
unnecessary energy consumption.
Automated production scheduling system: Adjust production plans in real-time
according to production needs, avoid equipment idling and excessive operation,
and reduce energy waste.
summary
The energy recovery and utilization measures in the production of quartz
plate sand mainly focus on waste heat recovery, electrical energy optimization,
wastewater recovery and reuse, process optimization, and the application of
renewable energy. These measures can not only significantly improve energy
efficiency and reduce production costs, but also reduce environmental pollution,
meeting the requirements of modern green manufacturing. By optimizing energy
use, recovering waste heat and wastewater, and introducing clean energy, the
quartz plate sand production line can be made more environmentally friendly,
efficient, and sustainable.