pfeiffer mvr cement mill for southern india

pfeiffer mvr cement mill for southern india

Gebr. Pfeiffer supplied almost 150 MPS and MVR mills to India, with customers headquartered in Delhi, Mumbai, Kolkata, Hyderabad, Ahmedabad and other cities, all of which are situated in Northern India. In terms of reference plants, Southern India was uncharted territory. Yet, with the order placed by Chettinad Cement, Gebr. Pfeiffer succeeded in winning a contract for a granulated blast-furnace slag and blast-furnace cement grinding plant, which will be set up near the steel works town of Visakapatnam. Key factors that influenced the buying decision of the end customer and his consultant HOLTEC included the very good references of Pfeiffers grinding plants in India, in particular those with the MVR 6000 C-6 mills, and also elsewhere in the world, the low energy consumption and the flexibility of the MVR mill. The active redundancy of the grinding rollers, which makes it possible to operate the mill with a reduced number of grinding rollers in the event of maintenance work or a malfunction, gives the cement producer the security of its plant having a high level of availability. The grinding plant now sold will be producing mixed cements with different proportions of clinker, gypsum, fly ash and granulated blast-furnace slag or grinding pure granulated blast-furnace slag or OPC. Depending on the product to be achieved, the capacity will range between 235 and 340t/h, with the products ground to fineness degrees between 3000 and 3800 cm/g acc. to Blaine. Gebr. Pfeiffer SE will supply the core components of the MVR 6000 C-6 mill as well as the 6700-kW gear unit from Europe. Foundation parts, housings and other components will be manufactured in India and delivered to the customer by Gebr. Pfeiffer (India) Pvt. Ltd., Pfeiffers wholly owned subsidiary.

Gebr. Pfeiffer supplied almost 150 MPS and MVR mills to India, with customers headquartered in Delhi, Mumbai, Kolkata, Hyderabad, Ahmedabad and other cities, all of which are situated in Northern India. In terms of reference plants, Southern India was uncharted territory.

Yet, with the order placed by Chettinad Cement, Gebr. Pfeiffer succeeded in winning a contract for a granulated blast-furnace slag and blast-furnace cement grinding plant, which will be set up near the steel works town of Visakapatnam.

Key factors that influenced the buying decision of the end customer and his consultant HOLTEC included the very good references of Pfeiffers grinding plants in India, in particular those with the MVR 6000 C-6 mills, and also elsewhere in the world, the low energy consumption and the flexibility of the MVR mill.

The active redundancy of the grinding rollers, which makes it possible to operate the mill with a reduced number of grinding rollers in the event of maintenance work or a malfunction, gives the cement producer the security of its plant having a high level of availability.

The grinding plant now sold will be producing mixed cements with different proportions of clinker, gypsum, fly ash and granulated blast-furnace slag or grinding pure granulated blast-furnace slag or OPC. Depending on the product to be achieved, the capacity will range between 235 and 340t/h, with the products ground to fineness degrees between 3000 and 3800 cm/g acc. to Blaine.

Gebr. Pfeiffer SE will supply the core components of the MVR 6000 C-6 mill as well as the 6700-kW gear unit from Europe. Foundation parts, housings and other components will be manufactured in India and delivered to the customer by Gebr. Pfeiffer (India) Pvt. Ltd., Pfeiffers wholly owned subsidiary.

Gebr. Pfeiffer (India) Pvt. Ltd., headquartered in Noida near New Delhi, will also assist the customer with the plant layout and procure a major part of the machines to complete the grinding plant, such as filter, fan, hot gas generator, fly ash handling and conveying equipment. Moreover, its skilled personnel will carry out the quality control of the parts manufactured on site and falling within the customers responsibility and supervise erection and commissioning.

Gebr. Pfeiffer (India) Pvt. Ltd., headquartered in Noida near New Delhi, will also assist the customer with the plant layout and procure a major part of the machines to complete the grinding plant, such as filter, fan, hot gas generator, fly ash handling and conveying equipment. Moreover, its skilled personnel will carry out the quality control of the parts manufactured on site and falling within the customers responsibility and supervise erection and commissioning.

mvr vertical roller mill for cement grinding

mvr vertical roller mill for cement grinding

Wonder Cement belongs to a family company based in Udaipur, India, which apart from other businesses is active in the cement industry. As Gebr. Pfeiffer already supplied 4 mills of the type MPS for raw material and pet coke grinding, the customer has now decided to use a vertical roller mill also for cement grinding.

Until now, the customer has used combined grinding plants of another supplier for grinding cement. Besides the lower specific energy consumption of the MVR mill, the fact that it can be used for grinding and simultaneously drying moist feed materials played a key role his buying decision. In India a trend towards the use of stored fly ash replacing more and more dry fly ash from coal power plants as cement constituent can be identified. This type of fly ash, stored in the open, has a very high moisture content and if processed in a grinding system different from the MVR mill would have to be dried separately. The customers engineering team called in HOLTEC, a consultant based in Gurgaon, close to New Delhi. Its good experience with PFEIFFER MVR mills which are in operation in other Indian cement works has led the consultant to suggest changing the grinding system and switching to a Pfeiffer MVR mill. Gebr. Pfeiffer SE, Kaiserslautern, will supply a mill of the type MVR 6000 C-6 with a 5,280 kW drive that will be set up in Nardana, in the state of Maharashtra. It will produce mixed cements with finenesses of up to 5%R 45 m. The customer was particularly keen on grinding relatively hot clinker in the mill while, at the same time, the cement outlet temperature is reduced. Added to this was the fact, that the concept offered the possibility of using cold clinker from stockpiles. The offered MVR mill, which is currently experiencing a high demand around the world, is equipped with six actively redundant grinding rollers. This means that all six grinding rollers take part in the grinding process. When it comes to scheduled maintenance works, two opposite grinding rollers can be swung out and the mill can continue production with the four remaining rollers. Even in the case of an unplanned outage of one of the grinding rollers, the mill can continue in operation while the roller under service is being worked on outside the mill.

Until now, the customer has used combined grinding plants of another supplier for grinding cement. Besides the lower specific energy consumption of the MVR mill, the fact that it can be used for grinding and simultaneously drying moist feed materials played a key role his buying decision.

In India a trend towards the use of stored fly ash replacing more and more dry fly ash from coal power plants as cement constituent can be identified. This type of fly ash, stored in the open, has a very high moisture content and if processed in a grinding system different from the MVR mill would have to be dried separately.

The customers engineering team called in HOLTEC, a consultant based in Gurgaon, close to New Delhi. Its good experience with PFEIFFER MVR mills which are in operation in other Indian cement works has led the consultant to suggest changing the grinding system and switching to a Pfeiffer MVR mill.

Gebr. Pfeiffer SE, Kaiserslautern, will supply a mill of the type MVR 6000 C-6 with a 5,280 kW drive that will be set up in Nardana, in the state of Maharashtra. It will produce mixed cements with finenesses of up to 5%R 45 m. The customer was particularly keen on grinding relatively hot clinker in the mill while, at the same time, the cement outlet temperature is reduced. Added to this was the fact, that the concept offered the possibility of using cold clinker from stockpiles.

The offered MVR mill, which is currently experiencing a high demand around the world, is equipped with six actively redundant grinding rollers. This means that all six grinding rollers take part in the grinding process. When it comes to scheduled maintenance works, two opposite grinding rollers can be swung out and the mill can continue production with the four remaining rollers. Even in the case of an unplanned outage of one of the grinding rollers, the mill can continue in operation while the roller under service is being worked on outside the mill.

The core components of the mill, such as tension system and grinding rollers, will be supplied by Gebr. Pfeiffer, Germany. The grinding bowl and the gearboxes for mill and classifier will also be supplied from Europe. The parts for housing and foundation, the supports for the grinding rollers and most of the parts of the integrated high-efficiency classifier of the type SLS 5600 BC will be provided by Gebr. Pfeiffer (India) Pvt. Ltd., Pfeiffers wholly-owned subsidiary in Noida. It will also supply most of the equipment required to complete the grinding plant, including plant fan. For all components which will be procured by the customer, he will receive the corresponding specifications. Delivery is scheduled to be effected before the end of this year.

The core components of the mill, such as tension system and grinding rollers, will be supplied by Gebr. Pfeiffer, Germany. The grinding bowl and the gearboxes for mill and classifier will also be supplied from Europe.

The parts for housing and foundation, the supports for the grinding rollers and most of the parts of the integrated high-efficiency classifier of the type SLS 5600 BC will be provided by Gebr. Pfeiffer (India) Pvt. Ltd., Pfeiffers wholly-owned subsidiary in Noida. It will also supply most of the equipment required to complete the grinding plant, including plant fan. For all components which will be procured by the customer, he will receive the corresponding specifications.

grinding of class-f fly ash using planetary ball mill: a simulation study to determine the breakage kinetics by direct- and back-calculation method - sciencedirect

grinding of class-f fly ash using planetary ball mill: a simulation study to determine the breakage kinetics by direct- and back-calculation method - sciencedirect

Mechanical activation of Class F fly ash using planetary ball mill.Bulk and surface characterization of milled ultra fine fly ash.Direct- and back-calculation method to estimate breakage parameters.Specific rate of breakage and energy-specific breakage rate for fly ash particles.Primary breakage distribution function for fly ash particles.

Dry grinding of Class F fly ash (FA) was carried out using the planetary ball mill to obtain mechanically activated nanostructured FA particles. The resulting FA powders were characterized for (i) particle size: dynamic light scattering and sieve analyzer, (ii) specific surface area: BET-analyzer, (iii) structure: X-ray diffractometer, (iv) chemical composition: field emission scanning electron microscope with the electron diffraction spectrum analyzer and x-ray fluorescence analyzer, and (v) aggregation and shape of the particles: Fourier-transformed infra-red spectrometer and scanning electron microscope. A significant enhancement in surface and bulk properties of milled FA was obtained over fresh FA. The breakage parameters (i.e., the specific rate of breakage and primary breakage distribution function) of FA were determined by the direct experimental method using the narrowly-sized fraction of FA over the short grinding period under identical milling environment. A relatively simple back-calculation method was employed to determine above breakage parameters of FA also using time-variant milling data that were obtained after the grinding of distributed-sized FA feed. The parameters obtained from the direct experimental and back-calculation method yielded comparative milling simulation results with the acceptable accuracy.

cement plant manufacturers, fly ash grinding ball mill manufacturers, hydratrated plant manufacturers - kohinoor engineer co

cement plant manufacturers, fly ash grinding ball mill manufacturers, hydratrated plant manufacturers - kohinoor engineer co

We are engaged in manufacturing, exporting and supplying various range of cement plants, grinding units, ball mills, etc. We are known for the features like durable construction, high performance and longer service life. The most updated technologies adopted highly experienced professionals employed and large .

investigation on grinding impact of fly ash particles and its characterization analysis in cement mortar composites - sciencedirect

investigation on grinding impact of fly ash particles and its characterization analysis in cement mortar composites - sciencedirect

The extensive usage of cement in almost all infrastructure projects will affect the health of construction industry around the world. At present, the entire globe is marching towards sustainable, eco-friendly and energy efficient infrastructure development with economic viabilities. The research elucidates the effect of grinding of Fly Ash (FA) and Ground Fly Ash (GFA) was studied. The fly ash particles are ground from 727cm2/g to 3526cm2/g specific surface area Ground fly ash were analyzed from the Blaines fineness test and particle size and optimized with 120min of grinding to achieve the ultra-fine particle size. The Cement replacement by 15% FA and 30% GFA were determined from the mechanical strength of blended mortar specimens. The investigation is aimed to increase the consumption of fly ash and enable to reduce the usage of natural resources for the cement production with ultrafine fly ash as an efficient replacement material.

L. Krishnaraj is Assistant Professor in Civil Engineering Department, SRM University, Kattankulathur. He obtained his B.E. degree in Civil Engineering from Adhiyamaan Engineering College, Anna University. He received his Post Graduate from SRM University. He has published over 20 research paper in national and international journals and conferences. He is life time member of Indian Concrete institute and Life member of Indian Society for Technical Education.

Dr. P.T. Ravichandran is Professor in Civil Engineering Department, SRM University, Kattankulathur. He obtained his B.E. degree in Civil Engineering from Madurai Kamaraj University. He received his Post graduation and Ph.D. from College of Engineering Guindy, Anna University. He has published over 70 research papers in National and International Journals and Conferences. He is a Life Fellow of Indian Geotechnical Society and Institution of Engineers (I) and Life member of Indian Society for Technical Education and Indian Road Congress.

cement mill and coal mill for wonder cement

cement mill and coal mill for wonder cement

Wonder Cement belongs to a family-owned company headquartered in Udaipur, India, which, apart from many other businesses, is active in the cement sector. Since 2010 Gebr. Pfeiffer has delivered five vertical mills for grinding cement, raw material and pet coke. Due to the positive experience the customer gained with the Pfeiffer equipment, the company decided to purchase two further vertical mills from Gebr. Pfeiffer.

One of the vertical mills ordered is an MVR 6000 C-6 for grinding cement. Up to now, Wonder Cement has used combi-grinding plants from another supplier. In addition to the better specific energy consumption of the MVR mill, another important factor in the customers decision to switch to the Pfeiffer grinding system was that even moist feed materials can be dried while being ground in the mill without any problems. This positive feature is of particular importance in India, because there is an apparent trend towards using stored fly ash as extender, replacing more and more dry fly ash from coal-fired power plants. Due to the outdoor storage, this fly ash has a very high moisture content and would have to be dried in an additional machine for other grinding processes. The engineering team of the customer received support by the consultant HOLTEC from Gurgaon near New Delhi. In the past, HOLTEC had also acquired extremely positive experience with Pfeiffer mills installed at other Indian cement plants, which is why a switch of the grinding system to the MVR mill was also recommended by the consultant. The ordered mill of the type MVR 6000 C-6 will feature a total drive power of 5820 kW and will be identical to the MVR 6000 C-6, which is currently being assembled for the same customer in Nardana in the state of Maharashtra. Mixed cements are to be ground to fineness degrees of up to 5%R45m. The grinding plant will be designed in such a way that not only granulated blast-furnace slag with a target fineness of approx. 4500 cm/g acc. to Blaine but also blast-furnace cements with different proportions of granulated blast-furnace slag, fly ash and gypsum and different product fineness degrees can be produced. It was important to the customer to grind relatively hot clinker in the mill while at the same time being able to reduce the cement temperature, and alternatively to use cold clinker from stockpiles.

One of the vertical mills ordered is an MVR 6000 C-6 for grinding cement. Up to now, Wonder Cement has used combi-grinding plants from another supplier. In addition to the better specific energy consumption of the MVR mill, another important factor in the customers decision to switch to the Pfeiffer grinding system was that even moist feed materials can be dried while being ground in the mill without any problems.

This positive feature is of particular importance in India, because there is an apparent trend towards using stored fly ash as extender, replacing more and more dry fly ash from coal-fired power plants. Due to the outdoor storage, this fly ash has a very high moisture content and would have to be dried in an additional machine for other grinding processes.

The engineering team of the customer received support by the consultant HOLTEC from Gurgaon near New Delhi. In the past, HOLTEC had also acquired extremely positive experience with Pfeiffer mills installed at other Indian cement plants, which is why a switch of the grinding system to the MVR mill was also recommended by the consultant.

The ordered mill of the type MVR 6000 C-6 will feature a total drive power of 5820 kW and will be identical to the MVR 6000 C-6, which is currently being assembled for the same customer in Nardana in the state of Maharashtra. Mixed cements are to be ground to fineness degrees of up to 5%R45m.

The grinding plant will be designed in such a way that not only granulated blast-furnace slag with a target fineness of approx. 4500 cm/g acc. to Blaine but also blast-furnace cements with different proportions of granulated blast-furnace slag, fly ash and gypsum and different product fineness degrees can be produced.

The core components such as the tension system and the grinding rollers will come from Gebr. Pfeiffer, Germany. The grinding bowl and the gearboxes for the mill and classifier will also be delivered from Europe. Gebr. Pfeiffers subsidiary, Gebr. Pfeiffer (India) Pvt Ltd., will provide the housing parts, the foundation parts and supports of the rollers as well as almost the entire high-efficiency classifier type SLS5600BC. Moreover, Gebr. Pfeiffer (India) Pvt. Ltd.s scope of supply will incorporate most of the equipment to complete the grinding plant including the plant fan. Delivery is scheduled for early 2019. Since Wonder Cement is also starting to expand its cement plant in Tehsil Nimbahera in the Chittorgarh district, the customer awarded Gebr. Pfeiffer a contract for another vertical roller mill for this plant. In Tehsil Nimbahera, the third rotary kiln with a daily capacity of approx. 8000tons will be operated with pet coke and/or coal as fuel. Gebr. Pfeiffer will supply an MPS mill for grinding the fuel. The extraordinarily good experience and the expert advice from HOLTEC also played an important role for this order. Pulverized pet coke will be used as fuel for the kiln. The pet coke will be ground in an MPS3070BK with a capacity of 40 t/h to a product fineness of 2%R90 m. Since the mill is equipped with an SLSBK high-efficiency classifier of the latest generation, both coal and pet coke can be ground in the mill, dried with process gases and then classified in the integrated classifier. Due to the high abrasiveness of Indian coal, the mill will be designed with appropriate wear protection. Most components of the coal mill will be supplied by Gebr. Pfeiffer (India) Pvt Ltd. The housing and foundation parts, the grinding bowl and a large part of the power-transmitting parts will be manufactured in India. Commissioning of the entire kiln line with the new grinding plant is slated for spring 2019.

The core components such as the tension system and the grinding rollers will come from Gebr. Pfeiffer, Germany. The grinding bowl and the gearboxes for the mill and classifier will also be delivered from Europe. Gebr. Pfeiffers subsidiary, Gebr. Pfeiffer (India) Pvt Ltd., will provide the housing parts, the foundation parts and supports of the rollers as well as almost the entire high-efficiency classifier type SLS5600BC. Moreover, Gebr. Pfeiffer (India) Pvt. Ltd.s scope of supply will incorporate most of the equipment to complete the grinding plant including the plant fan.

Since Wonder Cement is also starting to expand its cement plant in Tehsil Nimbahera in the Chittorgarh district, the customer awarded Gebr. Pfeiffer a contract for another vertical roller mill for this plant. In Tehsil Nimbahera, the third rotary kiln with a daily capacity of approx. 8000tons will be operated with pet coke and/or coal as fuel. Gebr. Pfeiffer will supply an MPS mill for grinding the fuel. The extraordinarily good experience and the expert advice from HOLTEC also played an important role for this order.

Pulverized pet coke will be used as fuel for the kiln. The pet coke will be ground in an MPS3070BK with a capacity of 40 t/h to a product fineness of 2%R90 m. Since the mill is equipped with an SLSBK high-efficiency classifier of the latest generation, both coal and pet coke can be ground in the mill, dried with process gases and then classified in the integrated classifier. Due to the high abrasiveness of Indian coal, the mill will be designed with appropriate wear protection.

Most components of the coal mill will be supplied by Gebr. Pfeiffer (India) Pvt Ltd. The housing and foundation parts, the grinding bowl and a large part of the power-transmitting parts will be manufactured in India.

ball mills manufacturers supplier in india. - lab ball mill (small ball mill) manufacturer from new delhi

ball mills manufacturers supplier in india. - lab ball mill (small ball mill) manufacturer from new delhi

Ball mill is mainly used for grinding in mining (metallic minerals and non-metallic minerals), cement, refractories, chemical, power plant, aluminum, building material, glass, ceramic, steel slag and fly ash, ect. It follows more crushing and less grindingprinciple to save energy. The feed size to ball mill shall be smaller than 25mm, the output size can be adjusted by revising steel balls ratio.Applied materials: copper, magnetite, molybdenite, zinc ore, iron ore, gold, hematite, fluorspar, lead & zinc, manganese, tungsten, marble, granite, slag, cement, limestone, clinker, coal etc.Different Types of Ball Mill:1. By Grinding Types: Wet Type Ball Mill & Dry Type Ball Mill2. By Discharging Methods: Lattice Type Ball Mill & Overflow Type Ball Mill3. By Installnation Methods: Horizontal Ball Mill & Vertical Roller Mill4. By Cylinder Types: Tube Type Ball Mill & Cone Ball Mill5. By Grinding Media: Steel Ball Mill6. By Sizes: Small Scale Ball Mill, Medium Sizes Ball Mill, Large Type Ball Mill7. By Grinding Material: Cement Mill, Air Swept Coal Mill, Ceramic Ball Mill, Dolomite Ball Mill, Raw Mill, Gold Ore Mill, Slag Ball Mill, Rod Mill etc.We are the manufacturer and exporter of the Girth gear, Pinion, Support Roller, Tyre, Bearing Housing, Complete Rotary Kilns Drive System for DRI coal based Sponge Iron rotary kiln 50 TPD, 100 TPD, 175tpd, 200 TPD, 300 TPD, 350 TPD, 500TPD, 600 tpd, Rotary Kilns Sponge Iron Plant.Used Applications : sponge Iron Plant, Sugar plant, cement plant, activated carbon plant, fertilizer plant, mineral plantMaterial:Cast Alloy Steel, Cast Carbon Steel, Forged Alloy Steel, Forged Carbon SteelStandard:ISO, EN, DIN, AISI, ASTM, JIS, IS, GBAdvantages:- Products with Customers' Designs- Strong Machining & Heat Treatment Abilities- Strict Quality Control- Prompt Delivery- Highly ExperiencedProcess:Forging/CastingNormalizing&Tempering-Proof MachiningQuenching&TemperingFinish Machining(Teeth Grinding)We can offer you in various process conditionsTesting process:QA documents: chemical composition report, mechanical properties report, UT report, heat treatment report, dimension check reportMain Export Markets:AsiaAustralasiaCentral/South AmericaEastern EuropeMid East/AfricaNorth AmericaWestern EuropeGlobal.

ball mills | air classification | united states

ball mills | air classification | united states

The company manufactures air classifiers, ball mills and stirred media mills for the production of fine, superfine and ultrafine powders for the mineral, mining, cement, lime, metal powder and chemical industries.

RSG Inc, manufactures air classifiers, ball mills and stirred media mills for the production of fine, superfine and ultrafine powders for the mineral, mining, cement, lime, metal powder and chemical industries.

development and characterization of coal fly ash through low-energy ball milling - sciencedirect

development and characterization of coal fly ash through low-energy ball milling - sciencedirect

A paradigm shift from monolithic materials to composite materials has been observed in recent times to achieve the ever changing demands of the manufacturing sector. The composites are being explored in terms of industrial and thermal power plant wastes used as reinforcements. Being a prominent thermal power plant waste, fly ash disposal and utilization is gravitating environmentalists and researchers to propose innovative ideas and feasible implementations. To trace and adjoin an effort to add value to aforementioned cause, an investigation was conducted on fly ash which was milled in tumbler ball mill with predefined input parameters viz. spindle speed, ball-to-powder ratio, and milling time. Low-energy mill has an extensive application in preparation of new materials, their activation and process of synthesis for potential merits like cost-effectiveness, reliability, low maintenance and ease of operation over its contemporary high-energy mill. The modifications in chemical and morphological properties of milled fly ash sample were characterized through X-ray diffraction (XRD) technique, scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX). The results inferred that the ball-milling process aimed at reducing crystallite domain size of milled fly ash, and also affected the microstructure, functional groups and led to decline in degree of crystallinity. The milling time was observed as a significant factor to impact extent of these changes. The particles of the raw spherical-shaped fly ash (regularly 5m size) were broken down into smaller particles of average crystallite domain size30nm, this change indicated an increase in amorphousness which helped in achieving better compatibility and significantly higher reactivity. The pattern and peaks of XRD for original crystallinites significantly diminished and resulted in broadened peaks. This can be interpreted by the smaller particle size and low degree of crystallinity. The research defined the achievement of nanostructured fly ash with low energy mill technique.

cement manufacturing plant - cement plant | agico epc cement

cement manufacturing plant - cement plant | agico epc cement

Concrete is one of the important building materials in the modern construction industry. It is manufactured after the mixing of cement, water, sand, and some other admixtures. Of them, cement is the most indispensable raw material. It is usually composed of limestone, clay, slate, blast furnace slag, iron ore, etc (different admixtures gives cement different properties). All these ingredients combined to form a hard substance by heating with a high temperature and then they can be ground into what we usually think of as a fine cement powder.

As a full-range supplier forcement equipmentin the cement manufacturing plant,AGICOhas mastered the advanced production technology and the ability to produce large-scale mechanical equipment from individual machines to complete plants. We provide various types of cement EPC projects and one-stop services for customers according to their requirements. To keep up with the changing situation of the industry, we have been strengthening the cement plant technology innovation, which not only ensures the environmentally sustainable development but also guarantees the health and safety of workers working environment.

The basic raw materials of cement manufacturing are calcareous material (CaO) and clayey material (SiO2, Al2O3, and a little Fe2O3). In the raw materials used to produce 1 tone clinker, the calcareous material accounts for about 80%, and the clayey material accounts for 10%~15%.

In the cement industry, calcareous materials refer to materials that regard calcium carbonate as the main component. It can be divided into natural and artificial (i.e., industrial wastes, like slag). The natural ore containing CaCO3 is the commonly used calcareous material in cement production, such as limestone, marl, chalk, marble, etc.

Clayey materials are the general term of raw materials containing water aluminosilicate. The natural clayey materials used in the cement industry include clay, loess, shale, mudstone, siltstone, and river mud. Fly ash is a kind of recycled and reprocessed material which can replace clay to save production costs

Corrective materials are used in small quantities only to adjust the chemical composition of the cement raw meal to meet the required quality targets. If an essential chemical component needed in the cement raw meal is not present in the required amount, corrective materials are used as additives. Generally, they can be classified into iron corrective materials, siliceous corrective materials, and aluminum corrective materials.

Gypsum (calcium sulfate dehydrate) is the most commonly adopted set-retarded material in cement manufacturing plants. It is generally added in a very small amount before the clinker is sent into a cement mill. Its main function is to prolong the setting time of cement otherwise the cement would set within minutes after mixing with water.

Except for the four materials we mentioned above, another important raw material is coal. It acts as the energy source in the cement manufacturing process. After mined, it should be further processed in the coal mill for more efficient burning.

Fly ash is the powdery ash after coal combustion in thermal power plants, and the slag is also formedafter coal combustion in industrial boilers. Their main components are SiO2 and Al203 and usually used in the cement manufacturing process for partially or completely replacing clay to participate in material batching, or used as aluminum corrective materials and cement mixture.

At present, the cement manufacturing processes can be divided into dry process and wet process. Their main difference is that in the dry process, raw meals are fed into the cement kiln in a dry state. While in the wet process, the raw meals are mixed with water in a slurry state. Regardlessofthemethodused, the first stage of cement manufacturing is always started from raw materials quarrying.

In the cement manufacturing process, the calcareous material and clayey material, as the basic raw material, will be excavated from open-pit mines near the cement plant after drilling and blasting. Then they will be fed into a crusher in the quarry, the product of which will be further transported to the cement plant, or they will be delivered to a crushing plant by trucks for further reduction in size. This depends on the raw materials particle size, economic factors, and the actual situation on the quarry.

After different kinds of raw materials are mined, they will get into a crushing stage. Cement crushers, we usually set the primary and secondary crushers, are the main equipment applied to crush raw materials until reaching an appropriate particle size, such as cone crusher, jaw crusher, hammer crusher, and roller crusher. Then the crushed materials are sent in a dryer for removing uncombined water. This step is typical of the dry method cement production process.

The pre-proportioning of raw materials is mainly finished in pre-blending yards. Crushed limestones are pre-blended and layered stacking on a circular pre-blend yard by stacker, and other addictive materials are on the longitudinal yard. Then a re-claimer will deliver them to their respective storage bins.

Raw meal grinding is a key part of the raw material preparation process. Varies types of cement raw mills are the main helper in this stage. The amount of each material received by the raw mill depends on the speed of belt conveyors which take the materials from their respective storage bin and feed them into the raw mill.After that, they will be ground into fine size. While, in the wet process, crushed raw meals are sent in wet grinding mills where a lot of water is added, these get ground to a fine, thin paste.

Homogenizing silo is a device used to mix raw meals by compressed air to get uniform chemical composition and fineness. It is the last homogenizing step in the line of the raw meal preparation processes. Besides, it also has the function of storage.

In the clinker calcination process, raw meals will be first sent into a preheater which is a device that reuses the hot gas discharged from kiln tail and calciner to preheat raw meals so that they can be partially calcined before entering the cement kiln. The preheater replaces partial functions of cement kiln, reduces the energy consumption and cost.

However, clinker burning still mainly occurs in the cement kiln, in which raw materials can be heated to 1500. In the heating process, the chemical interaction between raw meals will eventually lead to the formation of many gray spherical substances which we called clinker. These gray spherical substances are discharged with high temperature, so they should cool down to normal temperature by a cooler set behind the kiln.

After cooling, the ball shape clinker will be mixed with addictive materials, such as gypsum, limestone, etc., and then ground by cement mill. The final cement products are transferred to silos for storage and extracted by using a bucket elevator to be packed. Now, they are ready to be transported to various locations.

For different stages in the cement manufacturing process, AGICO offers various EPC projects of cement manufacturing plants: cement production lines, stone crushing plants, cement grinding units, fly ash processing plants, and VSK cement plant. All of these EPC projects can highly meet your needs for cement production with superior quality.

EPC refers to Engineering, Procurement, and Construction, which is an international general term of the general contracting projects. The EPC project service means that the project contracting enterprise shall be responsible for all stages of project construction, such as engineering design, equipment procurement, construction, commissioning, etc., according to the fixed or adjustable total price specified in the contract, and undertake the due obligations of quality, progress, cost and safety aspects of the project, finally submit a project meeting the use function and conditions to the owner.

In the cement industry, with the continuous technology upgrading and the intensification of market competition, more and more customers have turned their attention to EPC turnkey projects. One of the reasons is that the EPC project is more suitable for large projects with the engineering process as the main core. In addition, what are the other advantages of the EPC turnkey project compared with the traditional management model?

Centralized bidding reduces transaction costs, and in the project construction process, comprehensive management of the design, procurement, and construction also reduces the cost of the enterprise. In addition, it adopts a fixed-price contract which prevents contractors from adjusting prices because of changes in costs.

The EPC project management mode has a clear division of responsibilities, which reduces the risk of project loss or project failure caused by a conflict of interest. The owner is mainly responsible for the design, technical standards and the supervision of the contractor in the construction process, which bears little risk and is conducive to the project quality management, progress monitoring, and cost control.

When we adopt the EPC project, the project design, equipment procurement, engineering construction, and other links can be all cross-implementation by the contracting enterprises, so as to effectively reduce the construction period and improve the profit.

AGICO is a professional cement equipment and cement manufacturing plant supplier in China. We have more than 20 years experience in constructing cement EPC projects at home and aboard, which covers cement manufacturing plant design and construction, cement equipment production, installation, commissioning, and maintenance, personal training, and other services.

AGICO Group is an integrative enterprise group. It is a Chinese company that specialized in manufacturing and exporting cement plants and cement equipment, providing the turnkey project from project design, equipment installation and equipment commissioning to equipment maintenance.

ppc cement manufacturing process - portland pozzolana cement plant | agico

ppc cement manufacturing process - portland pozzolana cement plant | agico

What is Portland pozzolana cement? The hydraulic cementitious materials made of Portland cement clinker, pozzolanic material, and a proper amount of gypsum are all called Portland pozzolana cement (PPC cement). It is a kind of blended cement which is manufactured by mixing and fine-grinding silicate cement clinker, pozzolanic material, and gypsum.

Pozzolanic materials contain active silica and aluminum and usually do not have any cementitious properties. But when they are mixed with water and lime at ambient temperatures, they will react with calcium hydroxide to form compounds possessing cementitious properties. The commonly used pozzolanic materials can be classified as natural or artificial:

Portland pozzolana cement shall be manufactured by mixing and inter-grinding Portland cement clinker, pozzolanic materials, and gypsum. The manufacturing process is approximately the same as ordinary Portland cement, which can be divided into four processes: raw material crushing, raw material grinding, clinker calcination, and cement grinding.

Limestone and clay are the main material for Portland cement production. After mining, these raw material stones are unloaded by trucks and sent into crushers for reducing particle size. Then they are piled in a pre-homogenization yard waiting for processing.

Fine particle size raw materials are fed into the raw mill in a desired proportion for further particle size reduction, then they are stored in silos, meanwhile completing the material blending and homogenization process.

Cement raw meals are sent into a cement rotary kiln to be calcined under a high temperature. After several chemical reactions are produced, some spherical gray particles, what we called clinker, are formed. In cement cooler, these hot clinkers will be cooled to a normal temperature.

After cooling, the clinker is mixed with pozzolanic materials and gypsum in a required proportion and then sent to the cement mill for final grinding. The cement powder is usually stored in cement silos, then bagged and stored in the warehouse.

In the Portland pozzolana cement manufacturing process, we need a variety of cement equipment. AGICO, as a cement plant supplier in China, offers different cement solutions and cement manufacturing equipment.

Portland pozzolana cement, portland slag cement, and portland fly ash cement are all made by adding active admixture and an appropriate amount of gypsum based on Portland cement clinker. They are similar in nature and scope of application, so they can be used interchangeably in most cases. However, the physical properties and characteristics of the active admixture are different, which makes the three types of cement have their unique characteristics.

Slow setting and hardening, low early strength, and high late strength. The clinker content of the three kinds of cement is small, and the secondary hydration reaction is slow, while their later strength exceeds the ordinary Portland cement of the same grade.

Sensitive to temperature and humidity, suitable for high-temperature curing. When the three types of cement are cured at high temperatures, the hydration of the active mixture and clinker will be accelerated, and the early strength is improved without affecting the development of the later strength. Ordinary Portland cement, although the use of high-temperature curing can improve the early strength, the development of later strength will be affected.

Good corrosion resistance. They have good corrosion resistance and are suitable for the environment containing sulfate, magnesium salt, soft water, etc. However, when the corrosion resistance requirements are high, it is not suitable for the application.

Poor frost resistance. Slag and fly ash are easy to bleed to form connected pores. As to pozzolana, it has a large water storage capacity, which will increase the internal pore number. Therefore, the frost resistance of the three types of cement is poor.

Composite Portland cement: the early strength of composite Portland cement is higher than slag (or pozzolana, fly ash) cement, closes to ordinary Portland cement. It has low hydration heat, good corrosion resistance, impermeability, and frost resistance.

AGICO Group is an integrative enterprise group. It is a Chinese company that specialized in manufacturing and exporting cement plants and cement equipment, providing the turnkey project from project design, equipment installation and equipment commissioning to equipment maintenance.

cement plant manufacturer - cement plant manufacturer exporter, manufacturer, service provider, supplier, wholesaler & fabricator, delhi, india

cement plant manufacturer - cement plant manufacturer exporter, manufacturer, service provider, supplier, wholesaler & fabricator, delhi, india

We are one of leading manufacturer, supplier, design & engineering, equipment for cement plant . We are manufacturer & supplier various type of machines & Parts There of: apart from this we are providing service for assy, erection & commisioning:

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