5000T/D new dry process cement production line process equipment
The cement production line is a production line construction project composed of a series of supporting equipment for the production of cement. It is mainly composed of crushing equipment, homogenization equipment, raw meal preparation equipment, drying equipment, preheating decomposition equipment, clinker burning equipment, cooling equipment, grinding equipment, packaging equipment, conveying equipment, environmental protection dust collection equipment, etc. -Provide cement production line process design, civil construction, complete equipment, installation and commissioning, technical services, and general engineering contracting. The cement production line is a production line construction project composed of a series of supporting equipment for the production of cement. It is mainly composed of crushing equipment, homogenization equipment, raw meal preparation equipment, drying equipment, preheating decomposition equipment, clinker burning equipment, cooling equipment, grinding equipment, packaging equipment, conveying equipment, environmental protection dust collection equipment, etc. -Provide cement production line process design, civil construction, complete equipment, installation and commissioning, technical services, and general engineering contracting.
product description
The cement production line is a production line construction project composed of a series of supporting equipment for the production of cement. It is mainly composed of crushing equipment, homogenization equipment, raw meal preparation equipment, drying equipment, preheating decomposition equipment, clinker burning equipment, cooling equipment, grinding equipment, packaging equipment, conveying equipment, environmental protection dust collection equipment, etc. -Provide cement production line process design, civil construction, complete equipment, installation and commissioning, technical services, and general engineering contracting. The cement production line is a production line construction project composed of a series of supporting equipment for the production of cement. It is mainly composed of crushing equipment, homogenization equipment, raw meal preparation equipment, drying equipment, preheating decomposition equipment, clinker burning equipment, cooling equipment, grinding equipment, packaging equipment, conveying equipment, environmental protection dust collection equipment, etc. -Provide cement production line process design, civil construction, complete equipment, installation and commissioning, technical services, and general engineering contracting. The cement production line is a production line construction project composed of a series of supporting equipment for the production of cement. It is mainly composed of crushing equipment, homogenization equipment, raw meal preparation equipment, drying equipment, preheating decomposition equipment, clinker burning equipment, cooling equipment, grinding equipment, packaging equipment, conveying equipment, environmental protection dust collection equipment, etc. -Provide cement production line process design, civil construction, complete equipment, installation and commissioning, technical services, and general engineering contracting.
Process parameters
In the process of the cement production line, 3 tons of materials (including various raw materials, fuels, clinkers, mixtures, and gypsum) are required to grind for every ton of Portland cement produced. According to statistics, the grinding operation of the dry cement production line needs to consume The power of the plant accounts for more than 60% of the power of the whole plant, of which raw meal grinding accounts for more than 30%, coal grinding accounts for about 3%, and cement grinding accounts for about 40%. Therefore, reasonable selection of grinding equipment and process flow, optimization of process parameters, correct operation, and control of the operating system are of great significance for ensuring product quality and reducing energy consumption.
production method
Cement production uses limestone and clay as the main raw materials, which are crushed, batched, and ground through vertical milling to make raw materials, and then fed into the cement rotary kiln to calcinate mature materials, then add appropriate amount of gypsum to the clinker, and add some mixed materials. Or the admixture is ground into cement by a roller press and cement mill, and then transported by a packaging machine or bulk machine to leave the factory. Cement production equipment can be divided into dry cement production lines and wet cement production lines depending on the raw material preparation method. (1) Dry-process cement production process. The raw materials are dried and ground at the same time, or the raw materials are dried and ground into raw meal powder and then fed into the dry rotary kiln to calcinate the mature material. There is also a method of adding raw meal powder into a proper amount of water to make raw meal balls, and then sending them into the Liboer kiln to calcinate the mature material. This method is called semi-dry method, which is still a kind of dry method. The main advantage of dry production is low heat consumption. The heat consumption of dry kiln clinker with a preheater is 3140～3768 J/kg. The disadvantage is that the raw material composition is not easy to be uniform, the workshop dust is large, and the power consumption is high. (2) The production process of wet cement. The raw material is ground into raw material slurry by adding water powder, and then fed into a wet rotary kiln to calcinate mature material. There is also a method of dewatering the raw material slurry prepared by the wet method, and then making the raw material block into the kiln to calcinate the mature material, which is called the semi-wet method, which is still one of the wet method production. Wet production has the advantages of simple operation, easy control of raw meal composition, good product quality, convenient slurry transportation, and less dust in the workshop. The disadvantage is high heat consumption. The heat consumption of clinker is usually 5234~6490 J/kg.
Equipment contains
The main equipment of the cement production line includes: cement rotary kiln, cyclone preheater, cooler, crusher, vertical mill, roller press, cement mill, coal mill, dryer, dust collector, packaging machine, bulk machine, conveyor Machine, electrical control, etc.
crafting process
Pre-homogenization (1) Crushing: During the cement production process, most of the raw materials must be crushed, such as limestone, clay, iron ore and coal. Limestone is a large raw material for the production of cement. The particle size after mining is larger and the hardness is higher. Therefore, the crushing of limestone occupies a relatively important position in the material crushing of cement plants. (2) Raw material pre-homogenization: The pre-homogenization technology uses scientific stacking and reclaiming technology to realize the initial homogenization of raw materials during the storage and retrieval of raw materials, so that the raw material storage yard has the functions of storage and homogenization at the same time. In the process of new dry-process cement production, stabilizing the raw meal composition is the prerequisite for stable clinker firing, and the raw meal homogenization system plays a role in stabilizing the raw meal composition into the kiln. The preheating decomposition uses a preheater to complete the preheating and decomposition of the cement raw meal, replacing part of the functions of the rotary kiln, shortening the length of the rotary kiln, and realizing the air-to-material heat exchange process in the rotary kiln under the condition of suspended preheating. The material is fully mixed with the hot gas discharged from the rotary kiln, which increases the contact area of the gas and the material, has a fast heat transfer rate and high heat exchange efficiency, improves the production efficiency of the rotary kiln system, and reduces the heat consumption of clinker burning. (1) The material is dispersedly fed to the raw meal in the preheater pipe, and 80% of the raw material is exchanged in the inlet pipe. Under the impact of the high-speed ascending airflow, the material turns and moves upwards with the airflow and is dispersed at the same time. (2) The right of gas-solid separation. When the airflow carries the powder into the cyclone, it is forced to make a rotating flow in the annular space between the cyclone cylinder and the inner cylinder, and move downwards while rotating, from the cylinder to the The cone can be extended to the end of the cone, and then it will rotate upwards and be discharged by the exhaust pipe. (3) The emergence of pre-decomposition and pre-decomposition technology is a technological leap in the cement calcination process. It is to add a decomposition furnace between the preheater and the rotary kiln, use the rising flue at the end of the kiln, and set up a fuel injection device to make the exothermic process of fuel combustion and the endothermic process of the decomposition of carbonate of raw meal. The furnace is carried out quickly in a suspended state or a fluidized state, so that the decomposition rate of the raw meal into the kiln is increased to more than 90%. The carbonate decomposition task originally carried out in the rotary kiln is moved to the decomposition furnace; most of the fuel is added from the decomposition furnace, and a small part is added by the kiln head, which reduces the thermal load of the calcining zone in the kiln and extends the lining. The material life is conducive to the large-scale production; because the fuel and the raw meal are evenly mixed, the fuel combustion heat is transferred to the material in time, so that the combustion, heat exchange and carbonate decomposition processes are optimized. Therefore, it has a series of excellent performance and characteristics such as high quality, high efficiency and low consumption. After the fired raw meal is preheated and pre-decomposed in the cyclone preheater, the next step is to enter the rotary kiln for the firing of the clinker. In the rotary kiln, the carbonate is further rapidly decomposed and a series of solid-phase reactions occur to generate the minerals in the cement clinker. As the temperature of the material rises, the minerals will become liquid phase, and the dissolved in the liquid phase will react with each other to produce a large amount (clinker). After the clinker is fired, the temperature begins to drop. -The cement clinker cooler cools the high-temperature clinker discharged from the rotary kiln to the temperature that the downstream transportation, storage and cement mill can withstand, and at the same time recovers the sensible heat of the high-temperature clinker to improve the thermal efficiency and clinker quality of the system . Cement grinding Cement grinding is a post-process of cement manufacturing, and it is also a process that consumes a lot of electricity. Its main function is to grind the cement clinker to a suitable particle size to form a certain particle gradation, increase its hydration area, accelerate the hydration rate, and meet the requirements of cement paste coagulation and hardening. Cement packaging Cement is shipped in bags and in bulk. National standards require that the proportion of bulk cement must reach more than 70%, and the development of bulk cement is a major domestic trend.
Technical Parameters
Workshop name Host name Model, specification, performance
Limestone crushing Hammer crusher TKLPC20.22A Feeding particle size <1100mm, output particle size <75mm; production capacity: 700t/h
Siltstone crushing Jaw crusher PE-900X1200 Feeding particle size <750mm, output particle size <150mm; production capacity: 200t/h
Cone Crusher PYS-1215 Feeding particle size <150mm, output particle size <30mm; production capacity: 200t/h
Limestone pre-homogenization yard
Cantilever stacker
Bridge scraper reclaimer
Stacking capacity: 1400t/h
Reclaiming capacity: 500t/h
Siltstone pre-homogenization yard, mobile stacker, stacking capacity: 200t/h
Chain plate reclaimer Reclaiming capacity: 110--130t/h
Raw coal pre-homogenization yard, mobile trolley stacker, stacking capacity: 200t/h
Bridge scraper reclaimer Reclaiming capacity: 100t/h
Raw material grinding and waste gas treatment Vertical mill MLS4531, production capacity 360-400t/h; incoming mill moisture content <6%, exit mill moisture content <0.5%; incoming mill particle size <100mm, exit mill particle size: R80μm<12%
Raw material mill air volume: 860,000m3/h, total pressure: 9500Pa
High temperature fan at the kiln tail Air volume: 860,000m3/h, total pressure: 7500Pa
High-concentration electrostatic precipitator BS930type, electric field cross-sectional area: ~310 m2; processing air volume: 820000m3/h; outlet dust concentration (standard condition) ≤50mg/m3
Coal powder preparation Vertical mill MPF2116type, production capacity: 38~45t/h; water in the mill is <12%, moisture in the mill is <1%; particle size in the mill: <25mm, particle size in the mill: R80μm<12%
Firing system Rotary kiln
Φ4.8×74m, slope: 4%, number of supports: 3 gears; speed: 0.6~4.0r/min, installed power: 630kW; production capacity: 5000t/d
Preheater and decomposition furnace Five-stage double series preheater + decomposition furnace
C1: 4-Φ5.0m, C2: 2-Φ6.9m, C3: 2-Φ6.9m C4: 2-Φ7.2m, C5: 2-Φ7.2m; Decomposing furnace: Φ7.2x30.0m, production capacity : 5000t/d
Control flow grate cooler LBT36352, grate bed area: 119.6 m2; feed temperature: 1400℃, discharge temperature: 65℃+ ambient temperature
Kiln head electric dust collector Processing air volume: 550,000m3/h, electric field cross-sectional area: 196m2; inlet dust concentration: ≤30 g/m3; outlet dust concentration: ≤50mg/Nm3