3000 tons/day cement production line

It has successively completed the construction of more than 100 cement production lines, exported to more than 70 countries in the world, and has a global footprint. It sells products and provides one-stop solutions, including engineering design, civil construction, equipment complete sets, installation and commissioning, and production services. The EPC cement production line project includes services such as process design, equipment supply (including mechanical and electrical parts), civil engineering, installation and commissioning, trial operation, reaching production standards and final delivery. Mechanical equipment includes limestone crushing and conveying, clay crushing, auxiliary raw material pre-homogenization storage yard, raw meal batching station, raw material grinding and waste gas treatment, raw meal homogenization warehouse and raw meal kiln, firing kiln tail, firing kiln Middle and tertiary air duct, firing kiln head, clinker conveying, clinker storage and conveying, cement batching station and clinker bulk, gypsum, mixed material crushing and conveying, cement grinding and conveying, cement storage and conveying, cement packaging , Bagged cement loading, cement truck bulk loading, machine repair workshop and total material warehouse.

Process parameters

(1) Clinker output: ≥3000 t/d;

(2) Heat consumption of clinker firing

(3) Comprehensive power consumption of clinker

(4) Comprehensive electricity consumption of cement

(5) 28-day strength of clinker

(6) Dust emission concentration

production method

Cement production uses limestone and clay as the main raw materials, which are crushed and batched into raw materials, and then fed into the cement rotary kiln to calcinate mature materials, then add appropriate amount of gypsum to the clinker, add some mixed materials or admixtures, and pass the cement mill It is ground into cement, and then transported by packaging machine or bulk machine. Cement production equipment usually adopts dry cement production process. The raw material is dried and ground into raw meal powder at the same time, and then fed into the dry-process rotary kiln to calcinate the mature material. The main advantage of dry production is low heat consumption.

Process description

5.1 Limestone crushing

The plant has installed a limestone crushing plant. The quarried limestone is dumped by truck into a hopper made of concrete, and steel plates with bars are extracted by a heavy-duty skirt feeder, which has a processing capacity of 550 tons/hour.

The crusher is a hammer crusher with a capacity of 550 tons/hour. It can crush limestone blocks with a maximum size of 1000 mm to less than 75 mm. In order to prevent the crusher from overloading, the speed of the crusher feeder is changed through the hydraulic drive unit to respond to the power consumption of the crusher drive motor. Equipped with a scraper conveyor to collect the spilled material from the skirt feeder on it. The crushed limestone is transported to the circular pre-mixed bed through a belt conveyor. A belt scale with accumulator is provided to measure the crushing capacity. Provide pulse jet cleaning bag type dust collector for dust removal of crushing equipment.

5.2 Limestone pre-homogenization

The crushed limestone is stacked in a lateral cantilever type, with a stacking capacity of 600 tons/hour and a circulating storage capacity of 24,000 tons. Provide a bridge reclaimer with a capacity of 300 tons/hour for extracting limestone to the subsequent belt conveyor.

5.3 Crushing and transportation of auxiliary materials and coal

Additives (clay, iron ore, etc.) and coal will be transported into the factory by dump trucks. The crusher will be fixed in a covered warehouse. The skirt feeder feeds materials with a moisture content of less than 10 into the crusher. The crushed material will be transported to the long premix yard via a belt conveyor.

5.4 Additives and coal premix

The additives are dumped by trucks into a dumping hopper made of concrete. The lining bucket is lined with a steel plate with rods and extracted by a heavy-duty skirt feeder.

The crushed materials will be stored on the longitudinal material pre-mixing bed. A belt scale with accumulator is provided to measure the crushing capacity.

The coal is transported to the premix warehouse through a belt conveyor. These materials are stacked in a horizontal boom type to form two vertical stockpiles. Two cantilever reclaimers are provided for extracting the correction material to the subsequent belt conveyor for conveying to the raw material ratio hopper and coal hopper.

5.5 Raw material batching and transportation

The raw material batching station has 4 silos: limestone silos, mixed silos, clay silos, and iron silos. Below each bin, a weighing feeder automatically and steadily discharges materials from the bin according to a given ratio. The mixed raw materials are transported to the factory through a belt conveyor.

5.6 Raw material grinding and waste gas treatment

The vertical mill will be used for raw material grinding. The production capacity of the raw mill is 210t/h. The raw materials will be proportioned according to the set ratio, and then sent to the grinder for drying. The ground material will be carried by the air to the cyclone separator, and the coarse particles will be collected by the integrated separator and then sent back to the pulverizer for regrind. The dust-laden air from the cyclone will be processed in a bag filter before entering the atmosphere. The raw meal collected by the cyclone separator and the bag filter will be sent to the raw meal homogenization silo.

The hot air used to dry the raw materials will be drawn from the cyclone preheater.

5.7 Raw meal homogenization warehouse

The mixing system includes a multi-feed system and a continuous mixing silo with a capacity of 7,500 tons. The multiple feed system ensures that a uniform layer is formed across the entire cross section of the silo. The homogenization is affected by the funnel flow during the discharge process activated by circulating aeration in the bottom area. The hybrid system shows high homogenization efficiency and low energy consumption. The homogeneous raw meal is fed into the kiln feeding system in the bottom space of the mixing silo.

The homogeneous raw material is fed through the electric flow valve and belt scale, and then sent to the upstream pipeline of the preheater through the conveying equipment and bucket elevator. The air in the homogeneous silo should be provided by a Roots blower.

5.8 Kiln feeding system

The raw meal from the raw meal homogenization warehouse is sent to the weighing warehouse. After being measured by the impact flow meter under the hopper, the raw material is sent to the preheater system through a belt bucket elevator. When the kiln is temporarily stopped, the raw meal is returned to the raw meal homogenization warehouse.

5.9 Clinker Sintering System

Will use a Φ4.0x60m dry-process rotary kiln, which has a single series of 5-stage cyclone dust collector, precalciner and grate cooler. The system capacity is 2500t/d, and the heat consumption is 740kcal/kg. The raw meal is weighed and then sent to a preheater for preheating and partial decarburization, and then sent to a precalciner for calcination. The decarburization rate of CaCO3 in the raw meal at the entrance of the kiln is about 95%. The raw meal is further decarburized and burned in the kiln. The clinker whose temperature exceeds 1,350°C will enter the grate cooler for quenching. The clinker temperature at the outlet of the cooler is 65°C plus the ambient temperature.

The temperature of the exhaust gas discharged from the preheater is about 310°C and will be used to dry the raw materials. The exhaust gas from the cooler will be discharged into the bag filter for purification, and then discharged.

5.10 Clinker storage

The clinker is discharged from the cooler to the clinker hopper chain conveyor and transported to the 27,000-ton clinker silo. An unburned clinker barrel with a capacity of 500 tons will be installed inside the silo. The clinker will be transported to the clinker batching bin through a belt conveyor.

5.11 Crushing and transportation of gypsum and additives

Gypsum is transported from the mine to the site, discharged directly from the special discharge port, and then crushed in the PEX250×1000 crusher. When the crusher is turned off, the gypsum is kept in the special stockpile, and then sent to the unloading machine by the front loader. After crushing, the gypsum is sent to the silo through a belt conveyor.

5.12 Cement grinding

Clinker, gypsum, limestone or other additives are extracted from their respective hoppers in a predetermined proportion through a weighing feeder equipped with a speed controller.

Two units of φ3.8×13m ball mill are the main equipment of cement grinding department. The weighing feeder below the material box will feed the material according to the set ratio. The mixture will be fed into the mill via a belt conveyor. The ground cement material will be sent to the separator through a bucket elevator and an air slide. The finished product will be sent to the cement silo through the air slide valve, and the coarse particles will return to the ball mill. The exhaust gas discharged from the mill will be purified in a bag filter and discharged into the atmosphere.

5.13 Cement storage

Four cement silos with a diameter of 15m and a storage capacity of 20,000t. Cement from the cement plant is transported to the top of the silo by elevator. The cement in the silo reaches the intermediate silo through the sliding plate, and the cement discharged from the intermediate silo is transported from the cement bulk truck (3×150 t/h), and the other is transported to the cement packaging machine through the air chute.

5.14 Cement packaging

Two sets of cement packaging machines (8-port rotary packaging machine, 100t/h) will be used for cement packaging.

The dust caused by the packaging is collected by the bag filter, and sent to the bucket elevator through the screw conveyor, and then discharged into the packaging machine through the screw conveyor, and exhaust gas is discharged through the fan at the same time.

5.15 Coal powder grinding

The coal grinding system will use a ball mill. When the moisture content of the raw coal is ≤10%, the moisture content of the product is ≤1%, the particle size of the raw coal is ≤25mm, and the product fineness is 80m slag ≤10%, the output of the entire system is 18t/h.

5.16 Central control room and central laboratory

In the central control room, regular process operations and control will be performed, while in the central laboratory, quality control and testing of raw materials, fuels, finished products and semi-finished products will be carried out.

5.17 Air compressor station

An air compressor station will be installed and 5 screw booster air compressors will be installed with a displacement of 23m3/min and a pressure of 0.8Mpa to provide consumers in the production line with dry, oil-free and water-free compressed air.