Cement grinding station introduction
Cement grinding station is a production unit of cement finished products, which doesn’t include the last finished stage of the cement production process. Cement clinker and the right amount of mixing material are being mixed in this stage, and then cement is produced.
The raw materials for the cement clinker production are in the mine, and the mixed materials for the production of cement are in the industrial zone. Therefore, the cement enterprises often establish cement clinker production bases in the mining area, and cement grinding is built around the construction market in the city and town near the cement sales, thereby reducing the cost of transportation.
The production process of silicate cement is representative of cement production. It is made of limestone and clay as the main raw materials which are crushed, compounded and ground to make raw materials, then fed into the cement kiln to calcine, finally, add the appropriate amount of gypsum (mixed materials or admixtures) to grind into cement.
Cement grinding station flow chart
Advantages of cement grinding plant
This cement grinding station has some advantages such as stable production craftsmanship, good quality, high capacity, low energy consumption and so on.
- 1 Homogenize raw material components, reduce quality fluctuations to produce higher-quality cement clinker and stabilize the production of the firing system.
- 2 The quality and control requirements of mining can be reduced and the mining cost of the mine can be reduced.
- 3 It has a strong adaptability to sticky materials.
- 4 The high degree of automation.
- 5 Expand the utilization of mine resources, improve mining efficiency, expand the cover and interlayer of the mine, and produce no or less waste rock in the process of mining.
- 6 Provide long-term stable raw materials for the factory and different raw materials in the yard can be pre-allocated to make it a pre-mixing yard, creating conditions for stable production and improved equipment operation rate.
Advantages of cement grinding plant
The major equipment and process flow of cement grinding plant
1. Limestone crusher
The main component of limestone is calcium carbonate (CaCO3). Lime and limestone are used extensively as building materials and are important raw materials for many industries.
The crushed materials mainly have three methods of crushing, grinding and mashing. The crushing equipment used is a jaw crusher, a cone crusher, a roller crusher, a hammer crusher, an impact crusher and the like.
There are one, two or even three levels of crushing procedures. The use of several stages of crushing depends mainly on the technical performance of the crusher. Less crushing stages is better. However, regardless of the choice of the stages or the crusher, the discharge size of the limestone must meet the raw mill grinding requirements.
2. Cement kiln system
The cement kiln is the main equipment for cement grinding plant, and the whole process of turning raw materials into clink materials is completed in the kiln. The raw powder is added from the kiln tail. The pulverized coal is sprayed from the kiln head with primary air and burned in the kiln. The flame temperature here reaches 1800-2000 °C.
The raw material is continuously flowing to the head of the kiln, and the humidity is gradually increased. After drying, dehydration, preheating and decomposition, the liquid phase appears at about 1300 °C, and dried into clinker when the temperature is 1450 °C.
The material is then cooled to 1300~1100 °C and left the rotary kiln to fall into the single-tube cooler. It is cooled to about 100-150 °C and discharged to the clinker conveyor and transported to the clinker crusher. After crushing, it is stored in the warehouse.
3. Rotary kiln system
The rotary kiln is a cylinder rolled from a steel plate, which is internally reinforced with refractory bricks, supported by a wheel belt on the loading body and a lower idler wheel, and is driven by a large ring gear mounted on the kiln body.
The rotary kiln is usually placed at a slope of 3.5%, the number of revolutions is generally within 1 rev/min, and the new dry kiln is up to 3 rev/min. The temperature of the high-temperature zone of the kiln head was too high. It was previously cooled by water and has been changed to air cooling.
Rotary kiln system
4. Cement grinding station
If the process of cement production is regarded as a complete process system, the final product is cement and the clinker is semi-finished, so the system can be separated.
From raw material mining to mature material, it is a section. And from mature material to cement is the second paragraph. Under normal circumstances, the two sections should be put together, so that the land is less occupied, it is easier to manage, and there is less labor. However, it is more advantageous to separate in some special cases.
5. Cement ball mill
The ball mill is the earliest grinding equipment used in the cement grinding plant. It still dominates now. It has simple maintenance and high reliability. Especially for cement clinker grinding, product particle shape and grading are suitable and cement performance is good. It is difficult to find equipment that can be completely replaced.
Cement ball mill
The cement grinding process is the final process of cement manufacturing, and also the process that consumes the most electricity.
Its main function is to grind cement clinker (and gelling agent, performance adjusting material, etc.) to a suitable particle size (expressed by fineness, specific surface area, etc.) to form a certain particle gradation, increasing its hydration area and accelerating the hydration speed to meet the requirements of cement slurry condensation and hardening.
Cement grinding plant manufacturer - Fote Heavy Machinery
Fote Heavy Machinery provides limestone crusher and has many years of manufacturing experience in limestone crusher production, which has been successfully used in many limestone production lines. Fote has skillful crushing engineers and can design complete sets of limestone crushing line according to users’ requirements.
Fote provides a complete service including pre-sales consultation, design and installation, and limestone crushing system commissioning, trial production, and training for workers.
Cement grinding station produced by Fote Heavy Machinery
Customer case - Cement grinding plant in the United Arab Emirates
Processing materials: Cement
Daily running time: 8-20 hours
Production capacity: 300,000 tons/year
Equipment configuration: Jaw crusher, dryer, rod mill, cement mill, cement rotary kiln, belt conveyor and other equipment.
Production process: In the cement production line, first of all, the cement material needs to be processed by the crushing equipment. And then, it can be ground, dried and other multi-steps, finally make the cement clinker firing.
The raw material should be preheated and pre-decomposed in the cyclone preheater before entering the cement rotary kiln. In the cement rotary kiln, the carbonate is further rapidly decomposed and a series of reactions occur to form equal minerals in the cement clinker. Finally, it is transported by the belt conveyor to the product area.
Due to the high equipment configuration, the production line has the advantages of high efficiency, high automation, and pollution-free safety production.
Customer feedback: The customer purchased the whole set of cement production line equipment from Fote by recommendation. He said that the production line not only improved the overall output but had convenient maintenance of the entire production line without excessive worker operation and cost-saving.
Cement grinding plant on working plant