Mainly Technological Process Of 5000t/D Cement Production Line

Description of 5000t/D Cement Production Line

Cement production line is the production line composed by crushing equipment, homogenize equipment, raw material preparation equipment, drying equipment, preheat and predecomposition equipment, the clinker sintering equipment, cooling equipment, grinding equipment, packaging equipment, conveying equipment, environmental production dust collection equipment etc. We supply process design, civil construction, complete equipment, installation and trial run, technical services and the general contracting. The cement complete equipments are: 6000t/d cement production line construction, 5000t/d cement production line construction, 3000t/d cement production line construction, 2500t/d cement production line construction, 1500t/d cement production line construction, 600-1000t/d cement production line construction.

Parameters of 5000t/D Cement Production Line

The process of cement production is to grind three tons of materials for product and one tone of portland cement (including all the raw materials, fuels, clinkers, compound material and gypsum). According to the statistics, the grinding operation by cement dry process consumes 60% power of the the whole plant, and among it the grinding of the raw material occupies above 30%, the coal grinding occupies about 3%, the cement grinding occupies about 40%.Therefore, we should select grinding equipment and technological process reasonably, optimize technological parameters, and operate and control work system properly. It will play an important role in the reducing energy consumption.

Method of 5000t/D Cement Production Line

Limestone and clay are the main materials of the cement production which before becoming raw material are crushed, burdened and ground by vertical mill, and then become clinker by the cement rotary kiln, and then are put in appropriate gypsum, some mixed materials or admixture, and finally become cement through roller press and cement mill. After packaging by package equipment, the bulk cement will be transport out of the plant. Dry process and wet process are the two main production method.

The technological process of the dry process: put the dry raw material and grinding or dry raw material powder into the dry process rotary kiln. Another process named semi-dry method. During this process, appropriate water should be put into the raw material powder to make it become a ball, and then put it into the Lepol kiln.

The low heat consumption is the main advantage of the dry process. The heat consumption of dry process kiln with a preheater is 3140-3768J/KG. The weakness is that the raw material ingredient is not well-distributed, which means that the powder consumption in the workshop is high.

The technological process of the wet process: mix the raw material and water into raw material liquid and then put it into the wet process rotary kiln. Another process named semi-wet method. In this process, the raw material liquid should be dried into raw material chunk and then put into the kiln.

The wet process can be operated easily and the ingredient of the raw material can be controlled easily, and the production is high, the liquid is thick as well as the little dust in the workshop. The weakness is that the heat consumption is high, usually the clinker heat consumption is 5234-6490J/KG.

Equipment of 5000t/D Cement Production Line

The main equipment of cement production is: rotary kiln, cyclone preheater, cooling machine, crusher, vertical mill, roller press, cement mill, coal mill, dryer, dust collector, packaging machines, bulk machines, conveyors, electrical control etc.

Technological of 5000t/D Cement Production Line

Crushing: most of the raw materials need to be crushed, such as lime stone, clay, iron ore, coal etc during the process of cement production. Limestone is the most used raw material in cement production. The bigger particle size and the higher hardness make limestone an important position at the material crushing of cement plant.

Pre-homogenization: the pre-homogenization technology can ensure the raw material ground has the capability of storage and homogenization during the storage and reclaimer process of raw materials by scientific stacker and reclaimer technology.

Raw materials homogenization: stabilizing the raw material ingredient is the premise of clinker sintering. Raw material homogenize system is used for stabilize the raw material ingredient inlet the kiln at the process of dry process cement production.

Preheat and decomposition: use the preheater to preheat and decompose cement raw materials, replace part of the capabilities of rotary kiln and reduce the length of rotary kiln. When the raw materials are under the state of suspension and preheat, the raw materials and fervor gas exhausted from rotary kiln were intensive mixing, which makes the the contact area of gas larger, the heat transfer speed higher, heat exchange rate higher, production rate of rotary kiln higher and the heat consumption of clinker sintering lower.

The material dispersion: put 80% of the raw materials into the preheater pipe to exchange heat at the entrance of the pipe. Influence by the high speed updraft, the materials will turn up and disperse.

The gas-solid separation: the flow with material powder goes into the cyclone and was forced to rotate at the space between cyclone barrel and inside barrel while turning downwards.

The precalcining: The precalcining technology is a technological leap of cement calcination process. It is added between the preheater and calciner kiln. It can inprove the decomposition rate of kiln to 90%. The original task of carbonate decomposition is in the rotary kiln, and now it can be moved to the decomposition furnace; put the most fuel in the calciner and the rest in the kiln. It reduces the heat load of the kiln firing zone, extending the liner material life and the carbonate decomposition process can be optimized. So it is of excellent performance and high-quality, high efficiency and low power consumption.

Sintering: after the preheat the raw material, the next process is the clinker kiln firing. The carbonate becomes mineral material after a series of solid-phase reaction in rotary kiln. As the temperature of the material is close, the liquid will become minerals in the liquid phase reaction and generates a large number of clinker. After the clinker buring, the temperature begins to decrease. Finally, the cement clinker cooler unloading the kiln to the downstream transport, storage libraries and cement mill, improving system thermal efficiency and clinker quality.

Technical Specification of 5000t/D Cement Production Line

Shop name	Mainly equipment	Model, specification, performance
Limestone Crushing	Hammer crusher	TKLPC20.22A  Feeding particle size <1100mm,Discharging granularity <75mm ,Production capacity: 700t/h
Siltstone Crushing	Jaw crusher	PE-900X1200  Feeding particle size<750mm,Discharging granularity<150mm;Production capacity: 200t/h
	Cone crusher	PYS-1215 ;Feeding particle size <150mm;Discharging granularity<30mm ;Production capacity: 200t/h
Limestone pre-homogenization and storage yard	cantilever type stacker	Stack capacity: 1400t/h
	Bridge-type scraping reclaimer	Reclaimer capacity: 500t/h
Siltstone pre-homogenization and storage yard	movable-type stacker	Stack capacity: 200t/h
	chain-plate-type reclaimer	Reclaimer capacity: 110--130t/h
Raw coal pre-homogenization and storage yard	Car-moving type stacker	Stack capacity: 200t/h
	Bridge-type scraping reclaimer	Reclaimer capacity: 100t/h
Raw material grinding and waste gas treatment	Vertical mill	MLS4531;Production capacity360--400t/h;Moisture into the mill<6%;Moisture out of the mill<0.5%;Particle size into the mill<100mm;Discharging particle size :R80μm<12%
	Raw mill fan	Air volume：860000m3/h;Total pressure：9500Pa
	Kiln tail high temperature fan	Air volume：860000m3/h;Total pressure：7500Pa
	High concentration electrostatic dust collector	BS930type;Cross-section of the electric field：~310 m2;Disposing air volume：820000m3/h;Outlet dust concentration;Standard condition）≤50mg/m3
Coal powder preparation	Vertical mill	MPF2116type;Production capacity:38~45t/h;Moisture into the mill<12%;Moisture out of the mill<1%;Particle size into the mill:<25mm;Discharging particle size:R80μm<12%
Burning system	Rotary Kiln	Φ4.8×74m;Inclination：4%; Bearing number;Rotate speed
		：0.6~4.0r/min;Installed power：630kW;Production capacity: 5000t/d
	Preheater and calciner	Five pairs of preheater + decomposition furnace series
		C1：4—Φ5.0m ， C2：2—Φ6.9m，C3：2—Φ6.9m   C4：2—Φ7.2m，C5：2—Φ7.2m;Decomposition furnace:Φ7.2x30.0m;Production capacity: 5000t/d
	Grate cooler of control flow	LBT36352;Grate bed area: 119.6 m2 ;Inlet material temperature
		:1400℃;Outlet material temperature:65℃
	Electric dust collector at kiln head	Disposing air volume:550000m3/h;Cross-section of the electric field:196m2;Inlet dust concentration: ≤30 g/m3;Outlet dust concentration:≤50mg/Nm3