Cement Production Line

1. General introduction
1.1 Construction scale and production method
（1）construction scale
To construct a 3000t/d new type dry process cement production line. The annual output of high grade cement clinker is 900000 ton. The annual output of various cements is more than 1 million ton.
（2）production method
Use new type dry process pre-calcining kiln productive technology.

1.2Main technological and economic indicators

No.	Item	Unit	Indicator	Remarks
一 1	construction scale cement	ton/day	3000
二 1 2 3 4 5 6 7	Main production equipment Crusher TkPC4001.HR Raw material mill ф5.0×10.5M Rotary kiln ф4.3×64M Five stage cyclone pre-heater and calciner Clinker grate cooler Coal mill ф3.4×(6+3)M Cement millф3.8×13M	set set set set set set set	1 1 1 1 1 1 2	Equipped with roller press and scatter classifier
四 1 2 3 4	Whole plant indicator Equipment weight Installed capacity Annual power consumption Production water consumption	ton KW Ten thousand kilowatt/year m3/d	10080 28260 16830 2928
五 1	Total investment Fixed asset static investment including Construction engineering Equipment purchase Installation work Other cost
六 1 2 3	Unit product indicator Unit clinker material consumption Unit clinker heat consumption Unit cement power consumption	kg/kg KJ/kg Kwh/t	1.51 3344 102

2. Production technology
2.1 Brief instruction of process flow
（l）Limestone crushing and transportation
After been transported into plant, the outsourced limestone will be discharged in limestone stockpile or material bucket front of crusher. Then the limestone will be fed into a TkPC4001.HR hammer crusher for crushing. The crushed limestone will be transported into 3-φ15M silos for storage by belt conveyor and bucket elevator.
（2）Limestone storage and transportation
The crushed limestone will be transported into 3-φ15M silos separately according to different limestone component by belt conveyor at silo top. Silo bottom is equipped with constant feed weigher.
（3）Clay, shale and iron powder storage
The outsourced clay, shale and iron powder will be transported into stock shed for storage. The clay, shale and iron powder in stock shed will be transported into clay silo, shale silo and iron powder silo by bucket elevator.
（4）Raw material batching station
There are three batching silos in raw material batching station separately for clay, shale and iron powder. The silo bottom is equipped with constant feed weigher. After metering with material from limestone storage silo according to certain proportion, the materials will be transported into raw material grinding workshop by belt conveyor. The proportion of each material can be adjusted according to the content of outlet raw meal at any time to ensure the qualified rate of outlet raw meal.
（5）Raw material grinding and waste gas treatment
The matched raw material will be transported into a Φ5.0×10.5m drying mill by belt conveyor. The drying heat resource is the waste gas from pre-heater. The outlet gas will bring the fine powder into coarse powder classifier for classification. The coarse powder will return to mill for re-grinding. After classified in fine powder classifier along with air flow, the qualified fine powder will be transported into a Φ18m continuous raw meal homogenization silo by air slide, bucket elevator and silo top distributor. After metering, the outlet raw meal will be fed into kiln inlet pre-heater by elevator.
The high temperature waste gas discharging from pre-heater will be cooled to certain temperature by Φ9.5×30m conditioning tower. Most waste gas will be fed into raw material grinding workshop for drying heat resource by high temperature fan. The rest waste gas mixed with low temperature waste gas from raw mill will be purified by electric dust collector and discharged into atmosphere by fan. The dust concentration is less than50mg/Nm3. The dust collected by electric dust collector and conditioning tower will be transported into raw meal homogenization silo together with products from raw mill by spiral conveyor. When raw mill stops, they will be fed into kiln feed system.
（6）Raw meal homogenization silo and kiln feed raw meal
Establish a Φ18m multi-flow continuous raw meal homogenization silo with the capacity of 8300 ton. This silo top is mainly equipped with raw meal distributor and dust collector. The silo bottom mainly consists of aeration system, discharging device, flow rate control device etc. The outlet raw meal will be fed into raw meal steady flow silo by bucket elevator. The sensor of this steady flow silo and the flow rate control valve at homogenization silo bottom are combined into control circuit to control the raw meal in raw meal steady flow silo. The steady flow silo is equipped with flow rate valve and impact flow meter to control and measure raw meal. The metering raw meal will be transported into pre-heater system by belt elevator.
（7）Clinker burning and transportation
The kiln inlet use 5 stage cyclones pre-heater with H-I type online common calciner. After fed into pre-heater, the raw meal will be pre-heated and calcinered at the same time of movement from above to below. Then the raw meal will be fed into a Φ4.3×64m rotary kiln for burning. The calcining rate of raw meal is above 85%. The tertiary air of calciner is from kiln outlet (trough tertiary air duct). The temperature of tertiary air is 850℃.
Kiln discharge clinker is fed into a high efficiency grate cooler for cooling and crushing. Then the clinker will be transported to clinker silo by chain bucket conveyor. The temperature of cooler discharge clinker is ≤65℃ + ambient temperature. Part of waste gas from cooler is used to dry raw coal. The rest waste gas will enter into dust collector and be discharged into atmosphere after purification. The dust concentration of waste gas is less than 50mg/Nm3.
（8）Coal powder preparation and transportation
Raw coal storages in stock shed. The crushed raw coal will be fed into a Φ3.4×(6+3)m air swept mill by belt conveyor after metering. Mill discharge coal powder will be classified by coarse powder classifier. The coarse powder will return to mill for re-grinding. The fine powder will be classified by fine powder classifier. The classified coal powder will enter into two coal power silo. After metering by silo bottom constant feeder, the coal powder will be transported to kiln outlet burner and kiln inlet calciner by air slide. The waste gas will be purified by anti-explosion bag filter and discharged into atmosphere.
（9）Clinker storage and bulk
Clinker will be stored in a Φ40×35m circle silo with the capacity of 45000 ton. Install the bulk discharging device at the side of silo. The clinker will be delivered after metering.
（10）Cement grinding and transportation
The matched material will be fed into roller press by belt conveyor and elevator. It will be fed into 2 Φ3.8×13m high fineness cement mill after classified by scatter. Mill discharge cement will be transported into cement storage silo by bucket elevator.
（11）Cement storage and bulk
Cement will be stored in 6-Φ15×30m circle silo with the capacity of 40000 ton. After discharging from silo bottom, the cement is transported to cement packing workshop and truck bulk loading silo by chain conveyor.
（12）Cement packing and product storage
Cement will be packed by two eight-nozzle packer with the capacity of 100 ton per unit. The packed cement will be transported to product storage silo.

2.2 Storing capacity and period of various material

No.	Material name	Storing method	Storing capacity(t)	Storing period(d)	Remarks
1	limestone	Stock yard	20000	7
		3-φ15×26m	40000	8
2	Clay/shale/iron powder	Stock yard	3000	6
		Simple homogenization stock yard	4000	8
3	Ram meal	φ18×45m	8300	2.67
4	Clinker	Φ40×35m	45000	7
5	Gypsum/mixture	Stock yard	6000	10
		3-φ10×24m	4500	5
7	Cement	6-φ15×30m	40000	11
		72×120m Product storage	12000	3