What is pre-decomposition technology? The core of the new dry process cement plant is suspension preheating technology and pre-decomposition technology. The clinker pre-decomposition technology refers to adding a new heat source, precalciner, between preheater and cement rotary kiln. When the fuel is injected into the precalciner for combustion, the raw material preheated to about 750 by cement preheater is fed into the precalciner at the same time so that the exothermic process of fuel combustion and the endothermic process of carbonate decomposition in the raw meal is carried out rapidly. Generally speaking, the cement raw meal decomposition rate can reach more than 90% before entering the rotary kiln.
What is precalciner? Precalciner, also known as cement calciner, is a kind of high-efficiency direct combustion solid-gas heat exchange cement equipment. It disperses and suspends cement raw meal powder in airflow, making fuel combustion and calcium carbonate decomposition happen in a short time (generally 1.5 ~ 3 seconds). To some extent, it replaces part of the calcining work of a cement rotary kiln. In the calciner, because the fuel combustion and the material endothermic reaction are carried out at the same time, there is no visible flame, but in a state of low-temperature flameless combustion at 820 ~ 900 .
At present, more than a dozen types of precalciners have been put into use. Although each has its advantages, its characteristics and functions are similar. According to the different movement form of airflow, calciner in cement plant can be divided into four types:
The tertiary air with a temperature of 200 ~ 250 is blown into the air chamber of the fluidized bed calciner by a high-pressure fan and then enters the inner chamber through the air cap so that the fuel and raw materials form afluid-bed.
The preheated cement raw meal (temperature is about 820 ~ 860, not exceeding 860), a certain amount of fuel, and hot air (kiln tail flue gas or tertiary hot air) are fed into precalciner at the same time. After entering the calciner, the fuel and raw meals are dispersed by high-speed airflow and in a suspension state at about 900. The fuel is flameless combustion in the calciner, and the heat released by it makes the calcium carbonate in the raw meal decompose at a high speed through a convection heat transfer and radiation heat transfer. Generally, this decomposition process can be completed in a few seconds, and the decomposition rate of the whole raw meal is as high as 85% ~ 95%, forming an efficient operation mode of combustion, exothermic, endothermic, and decomposition at the same time.
Precalciner forms the clinker calcining system in the new dry process cement plant together with cement preheater, rotary kiln, and cement cooler. In addition to cement calciner, AGICO also provides other high-quality clinker calcination equipment, such as cyclone preheater, cement rotary kiln, grate cooler, rotary cooler, etc.
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 is also called cement manufacturing plant, which is a series of cement production equipment. It is mainly made up of crushing and pre homogenization, raw material preparation, homogenization of raw materials, preheating and decomposition, cement clinker burning, cement grinding as well as packaging process, which is the more complicated production process. The main equipment of cement production line includes cement rotary kiln and cyclone pre-heater, grate cooler, etc.
(2)Pre-homogenization of raw materials: pre-homogenization technology is to use scientific material piling technology to realize the preliminary homogenizing of raw materials and to make the materials stockyard have the combined function of storage and homogenizing during the process of storing and feeding of raw materials.
During the process of the cement production, the cement making machine needs 3 tons of grinding materials at least (including all kinds of raw materials, fuel, clinker, mixture, plaster) to produce 1 tons of silicate.
During the new cement production process, the stability of raw material component is in the premise of firing system. The homogenization system plays an important role in the stability of putting the raw material into the pit at the last line.
The preheating and parts of decomposition of raw materials are completed by the pre-heater to replace part of the rotary kiln function, shorten the length of the kiln and make the gas with accumulation state in the kiln conduct the heat transfer process. Therefore, it can be moved to the inner suspension pre-heater condition, which can mix the gas in the kiln completely, add the touching area, quicken the heat transfer and improve the efficiency of heat exchange to increase the productivity ratio and reduce the energy consumption.
After the preheating and decomposition in the pre-heater of the raw materials, the next process is to fire the clinker in the rotary kiln. The carbonate in the rotary kiln is further decomposed rapidly and it will cause a series of solid phase reaction, which will generate cement clinker minerals. With the increase of material temperature, the mineral will become liquid and they will be dissolved in the liquid phase and reaction to generate a large amount of clinker. After burning, the temperature of clinker begins to decrease. Finally the cement clinker cooling machine will convey the high temperature clinker discharged by rotary kiln to the withstand temperature of downstream transport, storage and cement mill. At the same time, the sensible heat and recovery of high temperature clinker will improve the heat efficiency and the quality of clinker.
Cement grinding is the last and the most power-consuming process. Its main function is to grind cement clinker (and gelling agent, performance adjustment material, etc.) to appropriate particle size (represented by fineness, specific surface area) to form certain granular level, increase the water area and accelerate the hydration rate of cement paste, so as to meet the condensation and hardening requirements.
Hongxing Machinery has cement plant for sale, which has high working efficiency, reliable performance and reasonable price. If you want to know more information about cement production, please contact our online customer service or send emails to [email protected],and we will answer you as soon as possible. Thank you!
The cement roller press is a kind of cement equipment for brittle materials, apply for cement clinker, and cement raw material, gypsum, coal, quartz sand, iron ore, blast furnace slag, and other materials.
The cement roller press is generally applied to the cement grinding plant, according to the real working process, cement roller press works with cement ball mill or vertical cement mill, which helps cement grinding plant to works well.
As new-type and energy-efficient cement grinding machine, cement roller press has advantages of energy-saving, high efficiency, less steel consumption and less noise. Both apply for new cement plant building and old cement plant revamping. According to the data, roller press helps ball mill system to increase the output by 30-50%. The 0.08mm fine material in the extruded material cake accounts for 20-35%, and smaller than 2mm accounts for 65-85%.
install the roller press in the cement grinding plant, the high pressure load is transmitted to the layer of the grinded material through the diameter of the double roller, most of the energy is used for the mutual extrusion between the materials. The sound energy and thermal energy generated by the friction of the material are transformed into the deformation energy of the material, which causes deformation, tearing and pulverization and fully utilize the potential of the cement grinding equipment, increase the output by 50-100%, and reduce the total energy consumption by 20%-30%. Promote the production efficiency of the entire system.
The material after grinding is greatly reduced in both particle size and the Bond function index, thereby greatly improving the grinding condition of grinding machine, and the power consumption of the entire cement grinding system is significantly reduced. It can save25-50% energy compared to traditional grinding methods, and the annual electricity saving are considerable.
Compared with the tube mill, the roller press is simple in structure, small in size, light in weight, and takes up less space in the workshop. It can save civil construction investment and also facilitate the original investment. In addition, the operation and maintenance of the roller press is very simple.
The material is squeezed and smashed continuously in the roller cover, and the harmful dust is not easy to spread. At the same time, the noise of the roller press is much smaller than that of the tube mill because of no impact.
The traditional tube mill is limited by processing, transportation, heat treatment and other conditions, and the large-scale tube mill is greatly restricted. The roller press grinding system solves such problems well.
The roller press works according to the principle of high-pressure layer pulverization, and adopts the work mode of single-grain pulverization. The brittle material is subjected to high pressure extrusion (the pressure of the machine in the pressure zone is about 150 MPa), the particle size of the material is rapidly reduced, the fine powder content of less than 0.08 mm reaches 20-30%, and the material of less than 2 mm reaches 70% or more, and a large number of cracks are present in all extruded materials, so that the energy required for the material to be ground in the next process is greatly reduced.
The main body of the roller press is two rollers that rotate in opposite directions, one is a fixed roller and the other is a movable roller. The brittle material is fed into the weighing chamber with the load cell by the conveying device, and then passes through the feeding device of the roller press into two rolls of the same size and opposite to each other, and the material is pulled into the nip by one side of the roller. The material is pressed into a dense material cake with high pressure, and finally falls from the nip, and is discharged from the hopper by the conveying device. The cake is further dispersed or ground by the next process.
Both the cementball mill and the cement roller press have their own advantages and disadvantages, but in actual production, the cement roller press has the advantages that the ball mill does not have, mainly reflected in the following points.
Note: Due to the large force of the roller of the roller press, the roller press has some problems, such as the material and the wear of the roller surface, the bearing is easily damaged, and the gear of the reducer is prematurely broken. In addition, the process operation process is strict. For example, the feed material column is required to be dense and full, and a certain feed pressure is maintained. The feed amount control should be appropriate, and the grinding process system configuration should be appropriate, otherwise its superiority cannot be exerted.
Cement plants with clinker capacity between 50tpd and 1000tpd can be called mini cement plants or small cement plants. Mini cement plants are very popular among small and medium-scale cement manufacturing enterprises since they do not require very large cement production capacities.
Our mini cement plants are designed to adopt the new dry process for cement manufacturing. The equipment in our mini cement plants mainly includes cement crusher, conveying equipment, preheater, rotary kiln, and cement grinding mill.
The cement crusher is the key equipment for raw material crushing. Because the sizes of just mined limestone (raw material for most cement types) pieces are too big, we have to crush them into small particles for cement manufacturing. The cement crushers that can be used in mini cement plants are hammer crusher, jaw crusher, roll crusher, cone crusher, impact crusher, etc.
The conveying equipment is an indispensable auxiliary device for material transportation in mini cement plants. Conveying equipment used in mini cement plants include bucket elevator, conveyors, and feeders.
A cyclone preheater is an important machine in new dry process cement plants. In cement production, the preheater uses the flue gas in the tail flue of the kiln to preheat the air in front of the kiln to a certain temperature, generating a heating surface through the internal heat sink, so as to improve the heat exchange performance of the kiln and reduce the energy consumption.
Rotary kiln is the most favorable cement kiln for new dry process cement plants, it is the place where the raw materials are calcined and burnt to cement clinker. The fuel burns in the rotary kiln to generate heat, which heats the materials through gas conduction or radiation. At the same time, as the kiln body rotates continuously according to the designed slope and rotation speed, the raw materials also periodically roll in the kiln and are transported from the feed end to the discharge end. The rotary kiln ensures that the raw materials are calcined into qualified clinker within the time of passing through, and achieves the purpose of high yield, high quality, and low energy consumption.
The hot clinkers discharged from the rotary kiln must be cooled before they can be transported and further processed. Rotary coolers and grate coolers are two types of clinker coolers that are often used in the cement industry today. We recommend rotary coolers for mini cement plants, cause they are more cost-effective in the small-scale cement production business.
The cement grinding mill is used in mini cement plants to grind the clinker from the cement kiln into fine powders. In our mini cement plants, the most used cement grinding mills are cement ball mill, Raymond mill, and vertical roller mill.
Mini cement plants are composed of low-yield equipment which is usually small-sized and covers less area. They can save a lot of land costs for the cement manufacturing enterprises. Small area coverage also leads to more flexibility in location choice. Cement plants can be built near mines where most large and medium-sized cement plants cannot be built, which means they can also help save a lot of raw material transportation fees.
The investment cost of a mini cement plant is lower than that of a medium or large-scale cement plant. It is because that the price of cement manufacturing equipment is relative to their capacities. Cement equipment with higher capacities generally is more expensive. And because the construction process of mini cement plants is simpler, the labor cost is also lower than medium and large-scale cement plants.
The equipment used in mini cement production lines usually possess small sizes, they are more convenient for transporting and assembly. So that the construction speed of mini cement plants is faster than that of large and medium-sized cement plants, which allows enterprises to start production earlier and benefit from the production faster.
AGICO Group has built dozens of cement plants around the world. The outstanding performance of our projects has earned us a high reputation across clients. Contact us for a professional cement plant solution now!
Cement plant refers to the professional cement production line to manufacture cement. What is your real need when you buy a cement plant? There are generally 5 aspects you may concern: cement equipment, cement manufacturing process, cement plant manufacturer, cement plant benefits, and related service.
AGICO CEMET is a cement plant manufacturer with rich experience from China. We can provide a one-stop EPC solution for your cement plant, including all cement equipment, design, installation, and service. Here are the reasons why you buy a cement plant from us:
As we all know, each cement production line has individual equipment on cement equipment. Based on lots of experience in cement plant projects and strong production ability, we can supply all types of cement equipment in cement plants.
A complete cement plant is generally composed of these steps, raw meal production, clinker production, cement grinding, and cement packing. (of course, you can have won step according to the real situation)
Who we are? AGICO CEMENT is a China cement plant manufacturer, our annual output reaches 150.000 tons of equipment and structure parts and 20,000 tons of casting parts. We have the Export & Import License and various types of certifications.
What do we offer? We have rich experience in providing EPC project for 50-10000 tons cement plant, one-stop service include cement plant design, cement plant equipment manufacture, cement plant installation and other customization service you need. High quality and competitive price are available.
the cement production line of AGICO CEMENT passes through long-term research and practice. Therefore, the whole cement production line has excellent performance, fast production speed, low energy consumption, and little pollution in the production process.
because of the good quality and excellent performance of each cement equipment in the cement plant, the wear situation and failure rate are low in the production process, which also makes the service life of the equipment longer;
AGICO CEMENT have provided the cement production line including design, manufacture, installation, debugging, and reaches producing standard project general contracting for many customers at home and abroad,
It is worth mentioning that we have our own large spare parts processing base, which completely meets your needs for supporting equipment. All products are safe and reliable, with a high degree of intelligence and environmental protection.
According to the environment, geology, climate, planning scientific and reasonable production line flow design for customers, to achieve the commitment of pre-sale service, in-sale service, after-sales service.
The cement manufacturing process also called the cement production process, in short, it is two grinding and one calcination. The limestone is broken, ground, and mixed into raw materials, and then it is calcined at high temperature to get clinker, and then clinker is ground with gypsum or other mixed materials into cement.
Dry process of cement manufacturing: raw material mining crushing drying ingredients grinding raw material storage homogenization calcination clinker cooling and crushing ingredients grinding cement storage and shipping.
Wet process of cement manufacturing: the main difference of this process lies in a section between raw material grinding and the kiln calcination, mainly for grinding raw material storage homogenization add water into ball calcination and so on.
New type dry cement production process: this process is strengthened homogenization in each storage link, mainly for raw material mining crushing pre-homogenization mixing grinding and drying raw powder storage homogenization calcination clinker cooling crushing clinker storage homogenization batching grinding cement storage homogenization shipping.
Cement plant is necessary for cement production, mainly consist of a series of cement equipment apply for preparation of cement raw materials, clinker production, and finished cement production, such as cement mill, cement crusher, rotary kiln, cement roller press, cement dryer, clinker cooler, cement silo, and related cement plant equipment. AGICO CEMENT is a cement plant manufacturer who owns ability to manufacture cement equipment and provide EPC turnkey project for cement plant.
AGICO Cement is a cement plant manufacturer with production capacity of 30,000 tons of equipments and structure parts and 20,000 tons of casting parts.own production equipment of 8m Vertical Lathe, 10m gear rolling machine, 8m Gantry milling machine, 200mm floor-type boring and milling machine,1203200mm bending machine, 150t crane and 40t electric furnace.Get in Touch with Mechanic