Cement production equipment

The main process flow and host configuration

1)   limestone crushing, conveying and storage. Limestone is broken by a MB56 / 75 crusher ( outdoor arrangement ) were broken. When the feeding ore maximum size is smaller than 1500mm, the particle size is smaller than 75mm, the crushing capacity of 500 ~ 600t / h; out of the limestone crusher by belt conveyor to a 80m circular limestone prehomogenizing storage yard ( reserve 34100 T ) for advance homogenization and storage, stacker ( heap material: 800t / h ), ring cantilever continuous cloth, reclaimer ( reclaiming capacity: 500t / h ) bridge, end, center of discharging material. After all of the limestone by belt conveyor to raw material proportioning station.

2)   auxiliary raw material storage, crushing and transportation. Auxiliary materials sand, iron ore from motor transport into the factory, unloading to the open yard storage. Among them, the sandstone open yard specifications for the 60 m x 20m, reserve 5100 T; iron ore open yard 32 m x 20m, reserve 2730 t. Sand, iron ore and a PC1609 hammer crusher, when the feed particle size is smaller than 600mm, the particle size is less than or equal to 25mm breaking capacity of 50 ~ 70t / h; the broken sandstone, iron ore by the belt conveyor to raw material mixing station ingredients stored in respective library. Auxiliary raw fly ash by bulk vehicle into the factory, by dumping system via pipeline into raw material proportioning station fly-ash base storage.

3)   raw material proportioning station. Raw material batching station with limestone, sandstone, iron ore, coal ash four ingredients Library ( specifications are 12 m ID, 25m, 220016002200770t reserves respectively ), bottom are respectively provided with a weighing feeder, by setting the mixture ratio of the material is calculated. With raw materials from the conveyor belt into the vertical grinding system for grinding.

4)   raw material powder and waste gas treatment. Raw material grinding mill using MLS3626 ( outdoor arrangement ), the drying heat source for a preheater waste gas. When the grinding particle size of raw materials 90% 75mm, product fineness of 80 u m square hole screen more than < 12%, into the grinding material water < 8%, < 1% of raw meal moisture, production system for 185t / h ( wear ). Raw meal by fine powder separator with humidifying tower and electric dust collector to collect the dust mixed, via a chute, bucket elevator to the raw meal homogenizing silo for homogenizing and storage; the grinding waste gas through the electric dust collector purification treatment, is discharged into atmosphere.

5)   raw meal homogenizing silo and kiln feeding. A qualified raw material by grinding the garage top raw material distributor multiple points of entry into a 18m x 50m CP ( effective reserves of 9000t ) of raw meal homogenizing silo homogenizing, through the discharging device quantitative unloaded into the kiln feeding system. Kiln feeding system is provided with a loading bin, bin has a metering and flow control device, after the measurement of raw material from bucket type lifting machine feeding into kiln preheater system.

6)   the clinker burning system and storage. Clinker burning system consists of low loss single series of online type five stage preheater and calciner ( RF5 / 2500 type, into the kiln decomposing rate of greater than 90% ), a 4 x 60m, LBT32216 new control flow grate cooler, are NCDRI technology. Among them : 1, kiln clinker with grate cooler cooling by chain bucket conveyor, into the 2 conveyer for 18 x 40m round Library ( effective reserves 2-10000t ) storage, warehousing clinker with unloading device, belt conveyor to cement clinker and cement batching station outside; 2, the hot end of the high temperature gas cooled machine part through the three duct into the decomposing furnace as decomposition furnace burning gas, The temperature of the heat into the coal mill as raw coal drying heat source; the tail end of the exhaust gas by electric dust collector purification before being emitted into the atmosphere, exhaust gas dust concentration ( converted into standard conditions ) is less than 100mg / m3.

7)   coal storage and transportation, coal powder preparation and delivery. Motor transport into the plant after the coal using 21m x 113m hanging garage (reserves 9300t ) storage and homogenizing. The garage is provided with two bunker, one is considering shortening the crane walking distance, on the other hand, is to consider the different quality of two kinds of coal collocation, bin bottom is provided with a weighing feeder, the measurement by the belt conveyor coal to the coal mill to grind. Coal powder preparation using a MPF1713 roller mill, outdoor arrangement, when ground water is less than or equal to 10%, coal moisture less than 1%; coal particle size is smaller than 50mm, pulverized coal fineness 80 u m square hole screen more than 11%, yield of 20t / h system. The mill pulverized coal with gas enters the separator separation, finished pulverized coal by the airflow into the air box pulse bag type dust collector collected by screw conveyor into two pulverized coal storage, waste gas after purifying the atmosphere. Pulverized coal bin is arranged at the bottom of coal powder measurement system, the measurement system of pulverized coal measures are fed into the kiln head and decomposition furnace combustion.

8)   slag drying and conveying, gypsum crushing and transportation. As the admixture of slag by car into the plant discharged into the open yard for storage, forklift slag into the bucket, the bucket elevator into the phi 2.4 x 18.350m dryer for drying, the drying capacity is greater than or equal to 30t / h ( the initial material moisture 20%, final 1.5% water ). Gypsum by motor transport into the factory, unloading to reserve 4000t open yard storage, after heavy slab feeder feeding PFC-1609 hammer crusher (when the feed particle size is smaller than 600mm, the particle size is less than or equal to 25mm production capacity of 50 ~ 70t / h) is broken, the broken gypsum by bucket machine, belt conveyor to gypsum bin storage.

9)   the cement grinding, transportation and storage. Cement batching station with gypsum, limestone and clinker, slag four ingredients for clinker silo, which is 10 m ID, 22m, 2000t reserves; gypsum slag pool library, and limestone are 8 m ID, 22m, reserves are 800, 400 and 900t. The reservoir bottom are respectively provided with a weighing feeder, by setting the mixture ratio of the material is calculated. Grog ingredient reservoir side a clinker bulk facilities, out for clinker. Four kinds of material in the feeding metering equipment according to the proportion of unloading, by belt conveyor to two sets by 3.8 dia x 13m mill with high Xiaoxuan powder machine consisting of a circular flow of cement grinding system for grinding, when the cement specific surface area is 3200 ~ 3400cm2 / g, a single set of production system for 75t / h; the abrasive material from the bucket into the high Xiaoxuan powder machine for sorting, coarse powder mill back to grinding, cement products by air box pulse bag type dust collector collected by air conveying chute, bucket elevator to 8 15 m ID, 34m cement base ( single storage for 5300t ) in storage. Cement grinding system for exhaust gas into the efficient air box pulse bag type collector is drained to the atmosphere after purification. Outbound cement consists of bottom unloading device after discharged, by a belt conveyor, bucket elevator, air conveying chute into the cement packaging workshop and bulk cement silo. The cement packaging uses two eight mouth rotary packing machine, packaging machine each ability for 90t / h, packaging bags of cement, the bag unloading conveyor system into 84m x 30m bagged cement products store inside the library ( reserves of 6000t ), also can be directly shipped loading. Bulk cement storehouse with two facilities for bulk cement trucks, bulk of car use.

The technical level and the main technical characteristics

(1) creative general layout. This project covers an area of limestone mine to close near the steep mountain slopes, not to occupy farmland, overall planning to meet the process smooth and reasonable at the same time, the original combination of fuel and cement products import factory direction, and taking into account the site topography feature and external traffic conditions, from west to East is sequentially provided raw fuel storage area, the main production line, planning to set aside the two phase of the production line, the front area, the district are arranged in parallel, functional partition is clear; and the height differential bench set District, beautiful visual effect. Another consideration of limestone mine is located in the west side of the higher terrain of the site, according to the characteristics and the combination of process flow, raw fuel storage area is arranged in the western higher locations, both to reduce the field leveling earthwork engineering quantity, but also shorten the belt conveying distance, improve land utilization rate, reduce the overall project investment cost. In addition, in order to avoid the middle of a flood ditch, overall planning, clinker production line and the cement grinding system are arranged on the sides of the trench to flood, belt machine for material transportation, which can meet the requirements of the process, and reasonable use of the terrain, avoiding flood ditch for the entire production line effect.

(2) selection of equipment in fully reflect the domestic and advanced and reliable, energy efficient. For example: 1 adopting a set of vertical mill as raw material grinding system, and compared with traditional ball mill system, the grinding efficiency is high, the drying capacity, low power consumption, investment and other significant advantages, in which only the power consumption with a ball mill system can achieve the unit yield compared to saving 4 ~ 6kWh / T, annual savings 4760000 - 7130000 kWh. To adopt vertical mill to replace the traditional air swept mill pulverized coal preparation system, the power consumption can be saved about 30%. The raw meal homogenizing silo with continuous homogenizing silo, the unit of raw meal consumption is 0.3kWh / T, intermittent mixing raw material of less than 0.4kWh / T. The kiln end with online type decomposition furnace of five stage cyclone preheater kiln feeding system, when the temperature is high up to 900 DEG C, into the kiln decomposing rate achieve 90% above, the clinker burning heat energy consumption control in 3137kJ / kg ( 750kCal / kg ) the following. The kiln head, in addition to the selected kiln tail sealing device, also adopted the new efficient three channel coal burner tube, through changing the air velocity and volume ratio, flexible adjustment of the shape of the flame and combustion intensity, in order to adapt to the condition in the kiln, thereby reducing the coal consumption, increase the yield. Clinker cooling using control flow reciprocating grate cooler, high thermal efficiency, energy saving and consumption reducing. The selection of high dust collecting equipment, pay attention to environmental protection, the factory discharges exhaust gas containing dust concentrations were lower than the national emission standard, which can save a large amount of raw material, fuel and power, saving energy, reducing environmental pollution of. The large fan, conveying equipment are selected in low-pow devices ( such as air chute to replace the screw conveyor ), reserve coefficient does not exceed the specified range. In addition to raw meal in preheater, pulverized coal, lump, all powdery materials are used to save the energy of mechanical transmission.

The production practice proved: this project adopts the new dry process production line system technology is mature and reliable, design optimization, debug successfully, general layout reasonable and concise and beautiful. Current annual run rate above 90%, the average yield reached 2730t / D above; heat consumption of clinker < 3136kJ / kg; a cylinder preheater outlet temperature less than 338 DEG C; resistance to 4590Pa; upon detection, all emission point emission concentration of the dust ( converted into standard conditions ) < 70mg / m3, benefit apparent.