Characteristics of Process Design:
Project: 4000t/d Cement Manufacturing Plant
Time: Sep, 2002-Sep, 2003
City: Baoji, Shanxi
Company: Yidong Cement Fufeng Co, Ltd
The project was constructed in the northwest of China at an altitude of 780m. Meanwhile, the geology on construction site is special which featured secondary collapsible loess.
- Limestone Crushing
Adopts PC2425 jaw crusher which is capable of reducing the size of limestone to less than 75mm
- Material Transportation System
A long belt conveyor is used for transportation which shortens the distance of the raw material transportation and reduces transportation costs.
- Raw Material Grinding
Equipped with a roller mill.
- Raw Material Inventory
Equipped with a bucket elevator to save energy, as well as to simplify the production process and control requirements.
- Clinker Burning System
Equipped with five-stage cyclone preheater and calciner (Φ6.6m×30.0m)
- Clinker Cooling
Adopts a grate cooler with 78 m2 of effective area of the grate bed and as high as 75% of heat recovery efficiency.
- Pulverized Coal Preparation
Equipped with a roller mill, resulting in a simplified production process, less energy consumption and reduced construction costs.
- Cement Grinding
Pre-grinding system, including 2 roller presses (Φ1.2m×800mm) and ball grinding mill (Φ4.2m×11m), resulting in less energy consumption. This pre-grinding system can not only produce various types of cement depending on the market demand at the same time, but can also operate at off peak hours to reduce production costs.
- Production Process Control
Equipped with a DCS distributed control system. The signal collection of production line and test , monitor and control of process parameters can be achieved by the PC control system formed by the field bus. Unnecessary measuring points are canceled according to actual production requirements. The cement packaging workshop is equipped with another control room.
- Plant Design
All materials except limestone are transported into or out of the plant by motor. To avoid endangering the safety of a great number of motor vehicles, there are 3 exits in the plant: exit for raw material, exit for finished cement and exit for staff.
|Main Parameters ||Design Value ||Acceptance Value |
|Capacity (t/d) ||≥4000 ||4300 |
|Clinker Specific Heat Consumption (kJ/kg-Cl) ||≤3011 ||3003 |
|Clinker Integrated Power Consumption (kWh/t) ||≤60 ||58 |
|Clinker 28 days compression strength (MPa) ||≥58 ||59 |
|Dust Density (mg/Nm3) ||≤100 (Kiln Head, Kiln Tail) ||95 (Kiln Head, Kiln Tail) |
|≤50 (Other) ||32 (Other) |
At present, the output of this project is more than 4300 t/d with stable operation and normal parameters.