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.
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