Process parameters

(1) Clinker production: ≥ 1500 t/d ； (2) Heat consumption: ≤ 840kcal/kg clinker
(3) Electricity consumption: ≤ 110kwh/t cement
(4) Water consumption: maximum 1020m3/d

Production method

Cement production mainly uses limestone and clay as raw materials, which are crushed, proportioned, and ground into raw materials through ball mills. Then, they are fed into a cement rotary kiln to calcine mature materials. The clinker is added with an appropriate amount of gypsum, mixed with some mixed materials or additives, ground into cement through cement grinding, and transported out of the factory by packaging machines or bulk machines. The dry cement production process commonly used in cement production equipment. The method of simultaneously drying and grinding raw materials into raw material powder, and feeding them into a dry rotary kiln for calcination into clinker. The main advantage of dry production is low heat consumption.

Host device

Process description
(1) Limestone and sandstone crushing
Limestone and sandstone are crushed by their respective crushers and discharged through belt conveyors
(2) Limestone pre homogenization and treatment
Crushed limestone is piled up in the pre homogenization greenhouse. Pre homogenized limestone is recovered by a reclaimer and transported to the raw material abrasive bin by a belt conveyor
(3) Sandstone storage and handling
Sandstone is crushed and stored in sandstone storage tanks. It is extracted from the storage bin by a belt extractor and transported to the raw material mill feed bin by a belt conveyor
(4) Clay storage and handling
During the dry season, clay is transported by truck from the quarry to the clay storage bin and stacked by bulldozers or loaders. Clay is retrieved from the storage bin by the loader, fed into the hopper, and transported by the belt conveyor to the raw material grinding feed bin
(5) Raw material grinding and transportation
The raw materials are extracted from their respective silos by belt scales (clay plates) and transported to the raw material grinding system by belt conveyors. Raw material mill is a closed-loop gas sweep ball mill The hot air discharged from the preheater serves as the heat source for drying the raw material mill. When the hot gas from the kiln or preheater is insufficient, there is also a backup oil furnace to supply hot gas
(6) Raw material homogenization into preheater
In the mixed silo, raw materials are homogenized to achieve the desired level of product consistency. The homogenized raw materials are sent from the batching bin to the preheater through the kiln feeding system, which consists of a level box, a flow valve, a weight meter, an air slide, and a bucket elevator
(7) Burning of clinker
Raw materials are heated and pre decomposed in a five stage preheater/calcination furnace, and enter the kiln during 90-95% decarbonization. The hot clinker in the kiln is cooled in the clinker cooler. The cold clinker from the cooler is transported by a bucket conveyor to two clinker silos Part of the exhaust gas from the clinker cooler is used as a heat source for the coal mill. The exhaust gas discharged from the grate cooler is partially used as secondary air to enter the kiln, partially used as tertiary air to enter the calcination furnace, and the remaining exhaust gas is discharged into the atmosphere after bag dust removal by the air-cooled heat exchanger
(8) Kiln/Raw Material Grinding Waste Gas Treatment
Part of the kiln preheater outlet exhaust gas serves as the heat source for the raw material grinding system. The remaining part, together with the raw material grinding waste gas, is discharged into the atmosphere after being dedusted by a bag filter c/w air-to-air heat exchanger. The dust collected in the bag room is sent to the homogenization warehouse or clinker warehouse
(9) Mud coal preparation and feeding system
After the mud coal arrives at the factory, it is piled up in a covered storage area using bulldozers or loaders. Mud coal is transported from the storage bin to the extraction funnel by a loader. The weighing feeder unloads the material to the belt conveyor, which transports the peat to the feeding bin of the mill
(10) Storage and processing of clinker
The clinker is extracted from the storage bin by a belt extractor and transported to the cement abrasive bin by a belt conveyor. The silo has two extraction points, one for each cement mill
(11) Storage, crushing, and handling of gypsum and volcanic ash
After arriving at the factory, crush, dry and stack the volcanic ash in the warehouse; Gypsum will also be crushed and stored. Gypsum and volcanic ash are both supplied from the warehouse by loaders and then transported to their respective cement mill feed bins through belt conveyors
(12) Cement grinding
Clinker, volcanic ash, and gypsum are mixed using a belt scale according to the set values, and the mixture is fed into a closed-loop cement mill using a belt conveyor. The ground product is transported to the cement silo by a bucket elevator. The gas outside the mill is discharged into the atmosphere after being dedusted by a bag filter
(13) Cement storage and transportation
Cement is stored in four equally sized silos. The silo has a conical bottom (not a flat bottom) and is equipped with an air cushion to ensure consistent extraction rates Cement is transported from the silo to the packaging plant through pneumatic slides and bucket elevators. Provide a bulk loading station equipped with telescopic chutes and dust collection devices; Feed only from one silo The packing device consists of two rotating 8-nozzle packing systems, each with a capacity of 100t/h. Bagged cement is loaded onto trucks or sent to the product warehouse through a belt conveyor. Each packer system can feed from two cement silos in an alternating manner
(14) Compressed air station
Compressed air is mainly used for bag filters, gas control valves, preheater groups, and pneumatic instruments. The total compressed air demand is 40 m3/min, with a pressure of 0.5~0.7 MPa. This site consists of 4 air compressors and supporting drying/filtering equipment, 3 in use and 1 standby. The capacity of each compressor unit is 15m3/min, and the exhaust pressure is 0.75mpa. Compressed air index: temperature<40 ° C, dust diameter<1 μ m, oil 0.01ppm, pressure 2-10 ° C
(15) Cooling water system
The water used for cooling comes from a water intake of the existing water system in the factory. The cooling water system is a closed-loop system to reduce consumption, consisting of circulating pumps, cooling towers, and water treatment.

Technical Parameter