Cement production plant, cement production line construction

 Cement production plant, cement production line construction

      The cement production line (cement plant) is a cement equipment production line composed by a series of equipment. This production line mainly consists of the process of crushing and prehomogenization, raw materials homogenizing, preheating decomposition, cement clinker firing, cement grinding & packaging.

     The main equipments used in this whole production line include the vibrating feeder, jaw crusher, impact crusher, cement ball mill lifer, preheating system, cement rotary kiln and packing machine and so on. All the cement equipment in this line can be provided by our factory.

1.Crushing and Pre-homogenizing:

        (1) Most of the raw materials, like limestone, clay, iron ores, and coal, should be crushed before their pre-homogenization. Limestone is the primary material in this line, and due to its large particle size and high hardness, its good crushing plays an important role in the whole line. Special stacking and reclaiming technology has been used in the pre-homogenizing process so that raw materials can be better primarily homogenized.

      (2)Raw material homogenizing: raw materials pre homogenizing is in the material piling up, by stacker to incoming raw materials continuously in a certain way piled material layer as much as possible parallel to each other, the upper and lower overlap and the same thickness. When, in the direction perpendicular to the material layer, as far as possible at the same time, cut off all material layer, in turn cut, until taken the end, namely "tile straight". The raw material yard has the functions of storage and homogenization

2.raw material preparation:

          (1)Raw materials: raw ingredients with limestone, sandstone, iron ore, four flyash base ingredient database (or other special materials library), base bottom are respectively provided with a weighing feeder, quantitative various materials are given according to the requirements of the production process ratio. By the belt conveyor into vertical mill  system for grinding.

       (2)Raw material grinding: the material through the lock feeding device by a feeding chute to disc center, under the action of centrifugal force was thrown to the edge of the grinding disc delivered by grinding roller rolling mill, the crushed materials from the disc edge overflow, is from the nozzle speed upward with the hot air flow drying up, according to the airflow velocity different, part of the material was taken to the air high efficiency separator, coarse powder after separation, returned to the grinding table, re grinding; fine powder qualified with gas out flow after grinding and increasing dust mixed wet tower and electric dust collection, through the chute, the bucket is sent to the raw meal homogenizing silo within elevator and storage.

3.Raw meterial homogenizing:

        Raw meal in a downward landed, with air agitation, gravity, produce "funnel effect", try to cut the multilayer surface, fully mixed. The use of fluidized air different, make the base surface occurred in parallel streams of different sizes of expansion effect, some regional discharge, some regional flow, so that the base surface is generated within the tilt, radial mixing. In the production process of cement raw meal composition, stable pit entry is the stability of clinker burning premise of thermal system, raw meal homogenizing system plays a stable raw ingredients into the cellar of the final control action.

4,Pre-heater and pre-calciner

         The raw material preheating and partial decomposition of the pre heater to complete part function, instead of the rotary kiln, the kiln to shorten the length of back, at the same time in the furnace to the accumulation state of gas feed heat transfer process, moved to the inner suspension pre heater condition, the raw hot gas can be exhausted with the kiln are fully mixed, increases the gas material the contact area, fast heat transfer speed, high heat exchange efficiency, improve the production efficiency of kiln system, reduce the heat consumption of clinker burning purpose.

       (1)the main function is to make full use of the pre heater kiln and pre calciner exhaust waste heat heating the raw material, the raw preheating and partial decomposition of carbonates. In order to maximize the efficiency of heat exchange between the solid and gas, to realize high quality, high yield, low consumption of the burning system, must have the solid gas uniform dispersion, heat quickly and efficient separation of the three functions.

        (2)pre decomposition: pre decomposition technique is a technical leap in cement calcining process. It is between the pre heater and calciner and rotary kiln kiln tail added by rising flue, a fuel injection device, an endothermic process to make fuel combustion exothermic process and raw material of carbonate decomposition, in the decomposition furnace with suspended or fluidized state quickly, so the raw meal decomposition rate increased to 90% the above. The original is in rotary kiln carbonate decomposition tasks, moved to the decomposition furnace; fuel mostly from the calciner to join, in part by adding less kiln head, reduce the heat load of the kiln calcining belt, prolonging lining life, is conducive to mass production; because of fuel and raw material mixing, fuel the heat of combustion of timely delivery to the material, so that the combustion, heat transfer and carbonate decomposition process optimized. So it has high quality, efficient, low consumption and a series of excellent performance and characteristics.

5.Clinker burning:

   The raw material is completed in the cyclone pre heater in preheater and precalciner, into the rotary kiln in the clinker burning. In rotary kiln is further decomposed rapidly and carbonate solid phase reaction of a series of cement clinker, generate AC3, AFC4, SC2 and other minerals. With the material temperature rise near C01300, AC3, AFC4, SC2 and other minerals will become liquid,dissolved in liquid SC2 and CaO reaction to generate a large amount ofSC3 (clinker). The clinker burning, the temperature began to decrease. Finally by the cement clinker cooling machine high temperature clinker cooling rotary kiln unloading to storage the set temperature for storage, sensible heat and recovery of high temperature clinker, improve system heat efficiency and the quality of clinker.

6. cement mixing station:

          Cement clinker, gypsum, station auxiliary materials storehouse, the guideline is respectively provided with weighing feeder, will give quantitative various materials according to the set ratio. Library side of clinker proportioning librarythe other with clinker bulk facilities, for external use of clinker. Material feeding metering equipment according to the proportion of discharge, by belt conveyor sent to the ball mill for grinding.

7.cement grinding:

           Cement grinding is the final process of cement manufacture, but also the most power hungry process. The main materials through the cement clinker (and gelling agent, performance adjustment material etc.) grinding to appropriate particle size (in fineness, specific surface area, such that the outlet material) by the bucket elevator into high efficiency separator in the sorting, coarse powder grinding to grinding, cement products by the air box. Pulse bag type dust collector to collect after by air transport chute, bucket elevator sent to a repository.

           Zhejiang Tongli Heavy Machinery Manufacturing Co.,ltd is specialized intechnology R&D, engineering consultation , equipment debugging, engineering contracting and related technical services for manufacturing cement, building material, mining, environmental protection, metallurgy, chemical equipment. Tongli Heavy Machinery  Co.,ltd established in 1958year, is a member of the China Building Material Machinery Association, a leading enterprise of China Cement Machinery, on the vendor of designated manufacturers for coal industry mechanical and electrical equipments, ISO9001:2008 accredited and accredited as a high-tech & new technology enterprise of Zhejiang Province, national designated “defend the contract heavy credit enterprise”, modern enterprise of national top ten cement grinding system of technologies and equipment , at the top of cement equipment manufacturing in Zhejiang Province.

       The Tongli Co.ltd occupies 153800m2 and the construction area of the workshop is 85000m2,the maximum lifting capacity of a single head crane is 200t. The company is equipped with more than 100 sets of heavy machinery manufacturing equipments such asφ5.3×18m(The lifting capacity is 200t)digital control horizontal lathe, φ5.5×18m lathe for machining shell, φ8m heavy digital display vertical lathe, φ8.0m heavy hobbing machine, 14×5m CNC vertical milling & boring machine, 3.4×10m CNC gantry milling & boring machine, 120mm digital control plate bending rolls, φ6.5×20m large size annealing furnace, φ6.5×20m sand blasting room, 1800t four columns hydraulic press, 10t electric arc furnace, etc, the integrated machinery processing ability is very strong.

          After working hard for more than 56 years, the company has the first-class science and technology development centers and craftsmen team who have much experience and skilled technology, specially manufactures series of cement machinery main equipments with independent intellectual property such as slag vertical mill, raw material vertical mill, cement vertical mill, coal vertical mill and rotary kiln, cement mill, wind swept coal mill, dryer, etc; in the meantime, manufactures the equipments and large- sized structural workpieces such as compound fertilizer, mining, power generating, sewage sludge (waste)incineration systems, etc, the products are exported widely toover 1000 companies from sixty or more countries such as Germany, Russia, Brazil, Egypt ,Iran, Bangladesh, Pakistan, Turkey, Myanmar, Vietnam, Columbia, Bolivia, South Africa, etc.