Raw material to Finished Product: Cement Production Line 10 Systems

Through ten carefully produced videos, this article comprehensively analyzes each link of the cement production line, introduces in detail the key equipment in the whole process from raw material crushing, pre-homogenization, raw material preparation, clinker burning to cement grinding, and deeply explains their working principles and operating points.

1.Raw Material Crushing System

Limestone is transported into the factory by car and unloaded into the limestone yard. Limestone is crushed by a heavy hammer crusher, which can directly crush large pieces of limestone with a maximum particle size of 1000mm to less than 70mm at one time. The entire crushing line is equipped with a bag dust collector to ensure a clean environment and meet environmental emission requirements. The raw material crushing process is simple, reliable and advanced.

2.Raw Material Homogenization and Storage System

The 200m*60m long pre-homogenization material yard is used, and the homogenization effect is good. The stacker and reclaimer adopts program automatic control, and the chemical composition of the limestone after homogenization is stable. The long pre-homogenization material yard is used in conjunction with limestone, and the homogenization effect is good. The stacker and reclaimer adopts program control according to the characteristics of the raw coal to achieve automatic operation. The chemical composition of the raw coal clay or sandstone after homogenization is stable.

3.Raw Material Batching System

Limestone, sandstone, clay, iron ore and other raw materials are selected for batching production according to the local raw material resources. The above raw materials are pre-homogenized and then enter the batching system. Electronic belt scales are used for precise measurement according to the special formula of cement. Advanced microcomputer batching system and quality monitoring instruments are used to track, monitor and adjust the quality in real time.

4.Raw Material Grinding and Waste Gas Treatment System

The vertical mill technology is adopted to make full use of the waste heat of the rotary kiln preheater exhaust gas to dry grind and grind the raw material in the vertical mill. The raw material after grinding has good quality, good controllability, low grinding power consumption, and is equipped with a cyclone dust collector group and a bag dust collector, and the environmental emission meets the standard.

5.Raw Material Homogenization and Kiln Feeding System

The φ15×35m continuous raw material homogenization storage technology is adopted to homogenize the row material after grinding again. The X-ray fluorescence analyzer is used to track and monitor the material quality and adjust the ratio of various raw materials in time to meet the product quality requirement.

6.Clinker Burning, Storage and Bulk Shipment

The clinker calcination adopts a single-row five-stage cyclone preheater and decomposition furnace system, a 4.2×65m rotary kiln with a combustion system, and a high-temperature kiln tail flue gas and raw materials are fully heat exchanged, with high thermal efficiency.

The clinker cooling adopts a fourth-generation grate cooler, with an inlet temperature of 1350℃, an outlet of 65℃+ambient temperature, and a thermal efficiency of over 70%. The waste heat of the exhaust gas is utilized by the coal preparation system and discharged through a high-temperature bag dust collector. The clinker is sent to two φ15×35m clinker silos for storage through a crusher and a chain bucket conveyor, and can be sold in bulk.

7.Coal Powder Preparation System

Utilize the exhaust gas and waste heat of the cooler and adopt the wind-swept coal mill to optimize the utilization of coal resources and reduce production costs and power consumption. Coal powder is flammable and explosive, and is equipped with an automatic monitoring alarm and fire extinguishing system. Anti-static bag dust collector is used, and dust emissions are far below the national standard.

The raw coal is transported in by car, stored in the pre-homogenization warehouse, and then transported to the coal mill head warehouse by the stacker and reclaimer. After metering, it is sent to the φ3.2×(6+3) meter wind-swept mill, and the coal powder is graded and separated. The coarse powder is returned to the re-grinding, and the finished product is pneumatically transported to the kiln head and decomposition furnace. The waste gas is purified by the bag dust collector and then discharged.

8.Cement Batching and Grinding System

According to the requirements of different cement varieties, clinker, gypsum and mixed materials are mixed with high-precision metering and then sent to the grinding equipment. The closed-circuit pre-grinding + high-fine open-circuit grinding system consisting of two sets of φ3.2×13m ball mills, roller presses, V-type powder selectors and cyclone collectors has high production efficiency, low energy consumption, large specific surface area and stable quality.

After the material is ground by steel balls, the qualified particle size is output by the discharging screw, the screen returns the unqualified material and collects the dust, and the screened material is transported by the bucket elevator. The whole process has a high degree of automation, excellent production parameters, good product quality, high output, low energy consumption, meets the high standard emission requirements of environmental protection, and has strong market competitiveness.

9.Cement Storage and Transportation System

After being ground by the grinding system, cement is stored in 6 φ15×32m cement silos with a total storage capacity of 6×6500t. Cement is delivered to the silo through bucket elevators and air transport chutes. The bottom of the silo is equipped with a pressure reducing cone and an air charging device, and the air is supplied by a Roots blower. The cement in the silo is delivered to the bulk and packaging system through the unloading device, air transport chute, and bucket elevator. Bag dust collectors are installed on the top and bottom of the silo to purify the dust-containing gas before discharge.

10.Cement Packaging and Truck Bulk System

After chemical and physical tests, qualified cement is sent to the central warehouse and bulk warehouse through elevators and air conveying chutes. The cement in the central warehouse enters the eight-mouth packaging machine and is measured by a microcomputer scale with high precision and good stability.
The packaged 50kg cement bags are sent to the bagged cement trucks for loading and leaving the factory through the conveying system such as the picker, leveler, and cleaner. Bulk cement is sent to two φ6×20m bulk warehouses through elevators and air conveying chutes. Each warehouse is equipped with a bulk loader and is directly loaded and shipped.