Cement Manufacture Plant

A cement production line is a cement equipment production line composed of a series of equipment for producing cement. It mainly consists of processes such as crushing and pre homogenization, raw material preparation homogenization, preheating decomposition, cement clinker burning, cement grinding and packaging.

process parameters
In the process of cement production line, at least 3 tons of materials (including various raw materials, fuels, clinker, mixtures, gypsum) need to be ground for every 1 ton of Portland cement produced. According to statistics, the power consumption of the dry cement production line grinding operation accounts for more than 60% of the total power consumption of the 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 flow, optimization of process parameters, correct operation, and control of operating systems are of great significance for ensuring product quality and reducing energy consumption.

production method
The production process of Portland cement is representative in cement production equipment. It mainly uses limestone and clay as raw materials, which are crushed, proportioned, and ground into raw materials. Then, they are fed into cement kilns to calcine mature materials, and the clinker is finely ground with an appropriate amount of gypsum (sometimes mixed with other materials or additives).

Cement equipment includes: cement rotary kiln, cyclone preheater, grate cooler
Cement rotary kiln is the main equipment for calcining cement clinker and has been widely used in industries such as cement, metallurgy, and chemical engineering. The equipment consists of a cylinder, a support device, a supporting device with a stop wheel, a transmission device, a movable kiln head, a kiln tail sealing device, a combustion device, and other components. The rotary kiln has the characteristics of simple structure, reliable operation, and easy control of the production process.
The grate cooler is a type of rapid cooling machine, which works by blowing cold air with a blower to rapidly cool the layered clinker laid on the grate plate, causing the clinker temperature to drop from 1200 ℃ to below 100 ℃. The cooled waste gas is then discharged into the kiln as secondary air.

Pre homogenization
(1) Crushing: In the process of cement production, most raw materials need to be crushed, such as limestone, clay, iron ore, and coal. Limestone is the largest raw material used in cement production, with a larger particle size and higher hardness after mining. Therefore, the crushing of limestone plays an important role in material crushing in cement plants.
(2) Pre homogenization technology for raw materials refers to the use of scientific stacking and retrieval techniques during the storage and retrieval process of raw materials, to achieve preliminary homogenization of raw materials and enable the raw material storage yard to have both storage and homogenization functions.
Raw material homogenization
In the production process of new dry process cement, stabilizing the composition of raw materials entering the pit is a prerequisite for stabilizing the thermal system of clinker burning, and the raw material homogenization system plays the final check role in stabilizing the composition of raw materials entering the pit.
firing
After the raw material is preheated and pre decomposed in the cyclone preheater, the next process is to enter the rotary kiln for clinker burning. In the rotary kiln, carbonate further decomposes rapidly and undergoes a series of solid-phase reactions, producing minerals such as minerals in cement clinker. As the temperature of the material increases, minerals will transform into a liquid phase, and those dissolved in the liquid phase will react to produce a large amount of clinker. After the clinker is burned, the temperature begins to decrease. Finally, the high-temperature clinker discharged from the rotary kiln is cooled by a cement clinker cooler to a temperature that downstream transportation, storage, and cement mills can withstand. At the same time, the sensible heat of the high-temperature clinker is recovered to improve the thermal efficiency and clinker quality of the system.

Preheating decomposition
Preheating and partial decomposition of raw materials are completed by preheaters, replacing some of the functions of rotary kilns, to shorten the length of the kiln. At the same time, the gas material heat exchange process in the kiln is carried out in a stacked state and moved to a suspended state inside the preheater, allowing the raw materials to fully mix with the hot gases discharged from the kiln, increasing the gas material contact area, fast heat transfer speed, high heat exchange efficiency, and achieving the goal of improving the production efficiency of the kiln system and reducing the heat consumption of clinker burning.
(1) Material dispersion
80% of the heat exchange occurs within the inlet pipeline. The raw material fed into the preheater pipeline is deflected upward by the high-speed rising airflow and dispersed.
(2) Gas-solid separation
When the airflow carries the powder into the cyclone, it is forced to rotate and flow in the annular space between the cyclone body and the inner cylinder (exhaust pipe), and moves downwards while rotating, from the cylinder to the cone, extending all the way to the end of the cone, and then turning upwards to be discharged through the exhaust pipe.
(3) Pre decomposition
The emergence of pre decomposition technology is a technological leap in cement calcination process. It involves adding a decomposition furnace between the preheater and the rotary kiln, utilizing the kiln tail rising flue, and installing a fuel injection device to enable the exothermic process of fuel combustion and the endothermic process of carbonate decomposition of raw materials to rapidly occur in a suspended or fluidized state inside the decomposition furnace, thereby increasing the decomposition rate of raw materials into the kiln to over 90%. Move the carbonate decomposition task that was originally carried out in the rotary kiln to the decomposition furnace; Most of the fuel is added from the decomposition furnace, with a small amount added from the kiln head, which reduces the heat load on the calcination zone inside the kiln, prolongs the life of the lining material, and is conducive to large-scale production; Due to the uniform mixing of fuel and raw materials, the combustion heat of the fuel is promptly transferred to the material, optimizing the combustion, heat exchange, and carbonate decomposition processes. Therefore, it has a series of excellent performance and characteristics such as high quality, high efficiency, and low consumption.

Cement grinding
Cement grinding is the final process in cement manufacturing and also the most power consuming process. Its main function is to grind cement clinker (as well as gelling agents, performance adjusting materials, etc.) to the appropriate particle size (expressed in fineness, specific surface area, etc.), form a certain particle size distribution, increase its hydration area, accelerate the hydration rate, and meet the requirements of cement slurry setting and hardening.
cement packaging
Cement can be shipped in two ways: bagged and bulk. The national standard requires that the proportion of bulk cement must reach 70% or more, and the development of bulk cement is a major trend in China.

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