100 tpd cement plant project cost

SHANGHAI SHIBANG MACHINERY CO., LTD is one high-tech enterprise, which involves R&D, production, sales and service as well. In the past 20 years, we devote to producing mining equipments, sand making machines and industrial grinding mills, offering expressway, rail way and water conservancy projects the solution of making high grade sand and matched equipments.

Production line equipment configuration

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Work flow of cement production line

Limestone is more commonly used in the cement preparation process, but the mined limestone generally has a larger particle size and needs to be crushed. In general, the processing of limestone into cement requires four raw materials: homogenization of raw materials, preparation of coal powder, calcination of clinker, and cement grinding stage.

  • 1. Homogenization of raw meal preparation: natural limestone, clay and peculiar raw materials are crushed by a jaw crusher and mixed according to a certain ratio, and then milled by a ball mill to prepare raw meals with appropriate ingredients and uniform quality;
  • 2. Preparation of pulverized coal: The coal required for calcining the raw meal of the cement must be prepared into pulverized coal to provide the particle size required for the combustion of pulverized coal in order to fully burn and obtain sufficient combustion reaction capacity. In this process, the coal powder can be fed directly, and equipment such as jaw crusher and ball mill will be used for processing.
  • 3. Clinker calcination: the raw lime is calcined in a rotary kiln until it is partially melted to obtain lime clinker.
  • 4. Cement grinding: Cement clinker is added into an appropriate amount of gypsum, mixed materials or additives to be ground into cement, and packed for shipment.

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Advantages of cement production line

  • 1. Low failure rate: The quality of each equipment in our cement production line is good, which can ensure the normal operation of the entire production line, and the failure rate is small;
  • 2. High-yield, low-consumption and small pollution: Our company’s cement production line is obtained through long-term research and practice. Therefore, the entire set of cement production line has excellent performance, fast production speed, low energy consumption, and low pollution during the production process;
  • 3. Long production line life: Because each equipment in the cement production line is of good quality and excellent performance, the wear and failure rates are low during the production process, which also makes the equipment longer in service life;
  • 4. Low labor input: The entire cement production line uses integrated automation equipment, so the labor required during the production line operation is small, which can reduce the cost of production input for the enterprise.

Process parameters

During the cement production line, at least 3 tons of materials (including various raw materials, fuels, clinkers, mixtures, and gypsum) must be ground for each ton of portland cement. According to statistics, the grinding process of dry cement production lines requires The power consumed accounts for more than 60% of the plant’s power, of which raw material grinding accounts for more than 30%, coal grinding accounts for approximately 3%, and cement grinding accounts for approximately 40%. Therefore, reasonable selection of grinding equipment and process flow, optimization of process parameters, correct operation, and control of the operating system are of great significance for ensuring product quality and reducing energy consumption.

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Production method

Portland cement production process is representative in cement production equipment. It uses limestone and clay as the main raw materials, crushes, mixes, and grinds it into raw meal, and then feeds it into a cement kiln to calcinate the mature material and then mature it. It is made by grinding a suitable amount of gypsum (sometimes with mixed materials or admixtures).

Depending on the raw material preparation method, cement production equipment can be divided into two types: dry method cement production line (including semi-dry method) and wet method cement production line (including semi-wet method).

  • 1 dry process cement production process. The raw materials are simultaneously dried and ground, or dried to be ground into a raw kiln and then calcined into a dry kiln. However, there is also a method in which the raw material powder is added into an appropriate amount of water to form a raw material ball, which is sent to the Lier kiln for calcining the mature material, which is called a semi-dry method, and is still a dry production method.
  • 2 wet process cement production process. After the raw material is added with water powder to form a raw slurry, it is fed into a wet kiln to calcine the mature material. There is also a method of dehydrating the raw slurry prepared by the wet method to form a raw material block into the kiln calcined mature material, which is called a semi-wet method, and is still a kind of wet production.

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The main advantages of dry production are low heat consumption (for example, the dry kiln clinker with a preheater has a heat consumption of 3140 ~ 3768 J / kg). The disadvantages are that the raw material composition is not easy to uniform, the workshop dust is large, and the power consumption is high. . Wet production has the advantages of simple operation, easy control of raw material ingredients, good product quality, convenient slurry transportation, and less dust in the workshop. The disadvantage is high heat consumption (the heat consumption of clinker is usually 5234-6490 J / kg).

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