Serial Number

Project Name

Equipment name, specification and technical performance

Yield (t/h)

Quantity

Annual Utilization (%)

1

limestone crushing

Heavy-duty plate feeder specification: B1250 × 11500mm, feeding size: 800mm, power: 30kw

200～350

1

25.51

Single-stage hammer crusher model: TKPC16.18, feed size: 800mm, discharge size: ≤ 25mm, power: 355kw

250

1

25.51

2

limestone pre-homogenization

Mixing stacker reclaimer, gauge: 24m, total installed capacity: 142kw

Stacking mode of stacker: continuous composite type, stacking layer number: >400
Form of reclaimer: full section reclaimer

600t/h
250t/h

1

3

Raw powder grinding

Vertical mill specification: HRM2800mm mm, grinding particle size: ≤ 40mm
Fineness of finished product: 0.080mm square hole sieve: 12%
In-grinding moisture: ≤ 6%, out-grinding moisture: ≤ 0.5, motor power: 1250 kw

130

1

60.90

4

Kiln and mill waste gas treatment

Specification of humidification tower: Φ7.5 × 26m, air volume: 400000m³/h
Inlet air temperature: 340 ℃, outlet air temperature: 150-220 ℃

1

82.19

High temperature fan flow: 400000m³/h, full pressure: 7500Pa
Use temperature: 340 ℃ (instantaneous 450 ℃), rotating speed: 1450r/min, motor power: 1250kw

1

82.19

2350DIBB24 high temperature fan, processing air volume: 300000m³/h 7500 Pa
C. BS930 electric dust collector:, processing flue gas volume: 400000m³/h
Inlet dust concentration: ≤ 80g/Nm^2,Outlet dust concentration: ≤ 50mg

1

82.19

Exhaust gas fan at kiln end, flow rate: 420000m³/h, full pressure: 1500Pa
Use temperature: 150 ℃, motor power: 355kw

1

82.19

5

firing kiln tail

Five-stage cyclone preheater and decomposer system
C₁: 2-Φ4300mm,C₂: 1-Φ5600mm,C₃: 1-Φ5600mm,C₄: 1-Φ5900mm
C₅: 1-Φ5900mm, decomposer: Φ6300mm

62.50

1

82.19

6

In the kiln

Rotary kiln specification: Φ3.5 × 54m
Slant: 4%, rotating speed: 0.4~3.96r/min, motor power: 220kw (DC speed regulation)

62.50

1

82.19

7

Kiln head clinker cooling

Air beam grate cooler model: LBTF1700

62.50

1

82.19

8

cement grinding

Specification of tube mill: Φ3.5 × 13m
Fineness of finished product: 320 m2/kg, main motor power: 2000kw

50

2

58.59

Type of powder separator: O-Sepa1500, air volume: 1500m³/min

2

58.59

9

Cement Packing

Eight-mouth rotary packaging machine metering accuracy: +/-0.25 kg/bag

90

2

34.18

The cement production line is a production line construction project consisting of a series of supporting equipment for the production of cement. It is mainly composed of crushing equipment, homogenization equipment, raw material preparation equipment, drying equipment, preheating and decomposition equipment, clinker firing equipment, cooling equipment, grinding equipment, packaging equipment, conveying equipment, environmental protection dust collection equipment, etc. Chaoyang Liaoxi Heavy Machinery Manufacturing Co., Ltd. provides cement production line process design, civil construction, complete sets of equipment, installation and commissioning, technical services, and general contracting.

In the process of cement production line, 3 tons of materials (including various raw materials, fuel, clinker, mixture and gypsum) need to be ground for every ton of Portland cement produced. According to statistics, the power consumed by dry cement production line for grinding accounts for more than 60% of the power of the whole plant, of which raw material 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, optimization of process parameters, correct operation, control of the operating system, to ensure product quality, reduce energy consumption is of great significance.

Cement production takes limestone and clay as the main raw materials, which are crushed, batched and ground by vertical mill to make raw materials, then fed into cement rotary kiln to calcine mature materials, then clinker is added with appropriate amount of gypsum, mixed with some mixed materials or additives, rolled by roller press and cement grinding into cement, and then transported out of the factory by packaging machine or bulk machine. Cement production equipment with raw material preparation method is different, can be divided into dry cement production line and wet cement production line two.

(1) Dry process cement production process. The method of drying and grinding the raw materials at the same time, or drying the raw material after grinding into raw material powder and feeding it into the dry rotary kiln to calcine the mature material. There is also a method of adding raw meal powder to the appropriate amount of water to make raw meal balls and sending them to the Lipohl kiln to calcine mature materials, which is called semi-dry method and is still one of the dry production methods. The main advantage of dry production is low heat consumption. The heat consumption of dry kiln clinker with preheater is 3140~3768 coke/kg. The disadvantage is that the raw meal composition is not easy to be uniform, the workshop dust is large, and the power consumption is high.

(2) Wet cement production process. The method of adding water to grind the raw material into a raw slurry and feeding it into a wet rotary kiln to calcine the mature material. There is also a method of dehydrating the raw slurry prepared by the wet method and then making the raw material block into the kiln to calcine the mature material, which is called semi-wet method and is still one of the wet method production. Wet production has the advantages of simple operation, easy control of raw material composition, good product quality, convenient slurry transportation, and less dust in the workshop. The disadvantage is that the heat consumption is high, and the heat consumption of clinker is usually 5234~6490 coke/kg.

The main equipment of 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, electrical control, etc.

pre-homogenization

(1) Crushing: In the cement production process, most of the raw materials are crushed, such as limestone, clay, iron ore and coal. Limestone is the largest amount of raw materials for the production of cement, after mining, the particle size is larger, the hardness is higher, so the crushing of limestone in the cement plant material crushing occupies an important position.

(2) Pre-homogenization of raw materials: Pre-homogenization technology is to use scientific stacking and reclaim technology to realize the preliminary homogenization of raw materials during the storage and retrieval of raw materials, so that the raw material yard has the functions of storage and homogenization at the same time. In the new dry process cement production process, stabilizing the raw material composition is the prerequisite for stabilizing the clinker firing, and the raw material homogenization system plays a role in stabilizing the raw material composition into the kiln. Preheating and decomposition use preheater to complete the preheating and decomposition of cement raw material, replace part of the functions of rotary kiln, shorten the length of rotary kiln, and realize the heat exchange process of gas and material in the rotary kiln under the condition of suspension preheating. Raw material is fully mixed with the hot gas discharged from the rotary kiln, which increases the contact area of gas and material, has fast heat transfer speed and high heat exchange efficiency, improves the production efficiency of rotary kiln system and reduces the heat consumption of clinker.

(3) pre decomposition. The emergence of pre-decomposition technology is a technological leap in the cement calcination process. It is to add a decomposing furnace between the preheater and the rotary kiln, use the kiln tail to rise the flue and set up a fuel injection device, so that the exothermic process of fuel combustion and the endothermic process of carbonate decomposition of raw material are carried out rapidly in the decomposing furnace in a suspended state or a fluidized state, so that the decomposition rate of raw material entering the kiln is increased to more than 90%. The carbonate decomposition task originally carried out in the rotary kiln is moved to the decomposing furnace. Most of the fuel is added from the decomposing furnace and a small part is added from the kiln head, which reduces the heat load of the calcination zone in the kiln, prolongs the service life of the lining material and is conducive to large-scale production. Due to the uniform mixing of fuel and raw meal, the combustion heat of fuel is timely transferred to the material, thus optimizing the combustion, heat exchange and carbonate decomposition process. Therefore, it has a series of excellent performance and characteristics such as high quality, high efficiency and low consumption. After the raw material is preheated and pre-decomposed in the cyclone preheater, the next process is to enter the rotary kiln for clinker firing. In the rotary kiln, carbonate is further decomposed rapidly and a series of solid-phase reactions occur to generate minerals such as cement clinker. As the temperature of the material increases, the minerals will become liquid phase. After the clinker is fired, the temperature starts to decrease. Finally, 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.

(4) cement grinding. Cement grinding is the final process of cement manufacturing and the most power consuming process. Its main function is to grind cement clinker to a suitable particle size, form a certain particle gradation, increase its hydration area, accelerate the hydration rate, and meet the requirements of cement paste setting and hardening.

(5) Cement packaging. Cement factory has two kinds of bagged and bulk shipping methods. National standards require that the proportion of bulk cement must reach more than 70%, and the development of bulk cement is a major trend in China.