In the cement production process, most of the raw materials are broken, such as limestone, clay, iron ore and coal. Limestone is the raw material for producing the largest amount of cement. After mining, the particle size is larger and the hardness is higher. Therefore, the crushing of limestone plays an important role in the material crushing of cement plants.

The material crushing process is more economical and convenient than the grinding process. It is very important to use crushing equipment and grinding equipment reasonably. Before the material enters the grinding equipment, the bulk material is broken into small and uniform particle size as much as possible to reduce the load of the grinding equipment and increase the output of the machine. After the material is crushed, the separation of materials of different particle sizes during transportation and storage can be reduced, and the raw materials with uniform composition can be obtained, and the accuracy of the ingredients can be improved.

1. The location of the material crushing system should be determined according to the plant resources, the external transportation conditions of the mine, the location of the plant, and the process layout.

2. The production capacity of the crushing system should be determined according to the raw materials of the plant, the annual fuel demand, the number of working days, the working system of the crushing system, and the imbalance of transportation.

3. The choice of crusher type and number of crushing sections should be determined according to the scale of the plant, material properties, mining particle size and product grain size requirements, abrasiveness and soil conditions.

4. The single-stage crushing system should use the hammer crusher or the impact crusher; the first-stage crusher of the second-stage crushing system should use the crusher such as the Dun type and the rotary type, and the second-stage crusher should use the hammer type, counter-attack type or cone type. Wait for the crusher.

5. The feed hopper capacity, form and geometry of the inlet and outlet before the raw material and fuel crusher should be determined according to the crusher specifications, capacity, material characteristics, vehicle model, load capacity and intermittent time.

6. The feeding equipment of large limestone should adopt heavy-duty plate feeder. The width should meet the requirements of ore particle size and crusher inlet width. The plate feeder should be able to start with heavy load and can be adjusted.

7. The discharge port of the crusher should be equipped with a conveyor belt conveyor. The width should be compatible with the size of the discharge port and the discharge amount. It should meet the instantaneous maximum discharge capacity of the crusher. It should be 1.3 ~ 1. times the capacity of the crusher. .

8. The raw material and fuel broken dust collector should be set according to the material characteristics, and the dust collector should return to the system.

9. The crushing workshop of auxiliary materials, fuels and mixed materials shall be arranged in the stacking shed. When arranged outside the stacking shed, it shall be connected with the stacking shed and the driveway shall be closed.

10. The number of segments of the silicon-aluminum and iron raw material crushing system and the crusher type should be determined according to the physical properties of the material, the mining granularity, the product size and the production capacity. When the mining particle size meets the requirements of human grinding, the crushing may not be performed.

11. The silo in front of the wet material crusher should be set as shallow silo, large discharge port, and larger bin wall inclination. Anti-burst liner should be set on the wall.

12. The selection of crusher for wet materials should be determined according to the physical properties of the materials, local climatic conditions and the adaptability of the crusher.

13. The crushing of coal should adopt a section of crushing system with screening. The crushing machine can be selected by hammer type, counterattack type or ring hammer type.

14. Gypsum crushing should adopt a section of crushing system. The crushing equipment can be of hammer type, counter-attack type and fine-type crusher. The feeding equipment should adopt a plate feeder capable of speed regulation.

First, the design of the production process and the selection of process equipment should meet the following requirements:

1 should be determined comprehensively according to production methods, production scale, product variety, original, fuel performance and construction conditions;

2 should choose to produce reliable, energy-saving and environmentally friendly process technology and equipment;

3 New technologies, new processes and new equipment that are conducive to improving the comprehensive utilization of resources and co-processing wastes should be adopted;

4 Under the quality requirements of finished and semi-finished products, the process links should be reduced and the material transportation distance should be shortened;

5 The selection of auxiliary machines should have reserves. Under the premise of ensuring production, the number of auxiliary machines should be reduced, and the models of similar auxiliary machines should be uniform;

6 Wear-resistant process equipment, non-standard parts, valves and ducts should be wear-resistant.

Second, the process layout should meet the following requirements:

1 The general layout should meet the requirements of the process, and should be combined with the conditions of terrain, geology and transportation;

2 The process layout should have reasonable development space;

3 The layout of the workshop should be comprehensively determined according to the process flow and equipment selection, and should meet the requirements of construction, installation, operation, maintenance, inspection and passage in the plane and space arrangement;

4 Equipment arranged in the open air shall meet the requirements of production operation, maintenance and repair, and safety protection.

Third, the material balance calculation should meet the following requirements:

1 The material balance calculation of the complete cement production line and clinker production line shall be based on the clinker production of the firing system, and the material balance calculation of the cement grinding station shall be based on the cement production;

2 In the material balance calculation of the complete cement production line and clinker production line, the consumption quota of various materials should meet the following requirements:

1) The dry consumption quota of each raw material shall be determined by the raw material consumption quota and ratio;

2) The consumption quota of raw meal should be composed of the theoretical consumption of raw meal and production loss;

3) The dry consumption quota of gypsum and mixed materials shall be calculated according to the blending amount in the cement and shall be included in the production loss;

4) The fuel consumption quota shall be calculated separately for the coal for firing and the coal for drying.

3 The dry material consumption quota should be converted into the wet material consumption quota according to the moisture of each material, and then the hourly, daily and annual dry and wet material requirements should be calculated.

4 In the calculation of the production loss of the complete cement production line and clinker production line, the production loss of coal should be calculated at 2.0%, and the production loss of other materials should be calculated at 0.5%. The production loss of all materials in the cement grinding station shall be calculated at 0.5%.

Fourth, the annual design utilization rate of major process equipment should be determined according to the size of the plant, the complexity of the production system, the type of host, the source of the equipment, the conditions of use, etc., and meet the requirements of the following table:

Serial number Main process equipment name Annual utilization rate(%)
1 Rotary kiln ≥85
2 Raw material mill 70~80
3 Cement mill 70~85
4 Coal mill 60~75
5 Limestone crusher 20~50
6 Cement packaging machine >20

Fifth, the main production system work system should be determined according to the relationship between the systems and the conditions associated with external conditions, and meet the following requirements:

Serial number Main production system name Working days per week(d) Daily work shift
1 Limestone crushing 5~7 1~2
2 Limestone pre-homogenization (stacking) 5~7 1~2
3 Limestone pre-homogenization (recovery) 7 3
4 Raw material grinding 7 3
5 Raw material homogenization and kiln 7 3
6 Pulverized coal preparation 7 3
7 Clinker burning 7 3
8 Clinker storage and transportation 7 3
9 Cement grinding 7 3
10 Cement storage 7 3
11 Cement packaging and bulk 5~7 1~3
12 Coal, gypsum, silicon-aluminum raw materials broken 5~7 1~2
13 Compressed air station 7 3

Note: The work shift system is based on 8 hours per shift.

In the case of non-cooperative disposal of waste and no bypass and venting, the energy efficiency design index of the clinker firing system of various scale production lines of precalcining kiln shall comply with the current national standard “Cement Factory Energy Conservation Design Specification” GB 50443 Provisions.

Sixth, the performance evaluation of the host should be carried out under the design conditions of raw materials, fuel composition and performance. The performance requirements of the host should meet the following requirements:

Production system Checking time Examination content
Raw material grinding system 2*18h Average hourly output, raw meal fineness, moisture, power consumption per unit of product
Cement grinding system 2*18h Average hourly production, cement specific surface area, pass rate, system product power consumption
Firing system 72h Average daily production, clinker burning heat consumption, clinker quality (free calcium content, 3d and 28d strength), cooling machine clinker temperature, unit product power consumption

Seventh, the maintenance facilities of the production workshop shall meet the following requirements:

1 The inspection equipment of the main equipment shall meet the following requirements:

1) When the components to be repaired are large in the crusher, the transmission device of the grinding equipment, and the series mill with the factory building, lifting equipment such as bridge cranes and suspended cranes should be installed;

2) Above the equipment such as large fan, classifier, car press and other equipment with factory building, electric hoist, single beam crane or other types of lifting equipment should be installed;

3) The hoist should be set up on the head of the hoist.

2 The lifting capacity of the lifting equipment shall be determined according to the weight of the assembly that is the heaviest lifting or the lifting of the assembly.

3 The height of the rail top of the crane and the height of other lifting facilities shall meet the requirements for the maximum lifting height of the lifting object.

4 The design and equipment layout of the plant shall not affect the operation of the lifting and lifting facilities and the lifting of the objects.
5 The maintenance platform or the transportation space required for the installation and maintenance of the space, the door opening and the equipment transportation and maintenance shall be set according to the installation and maintenance requirements of different equipment.

Eighth, the material transport design should meet the following requirements:

1 The selection of material conveying equipment should be determined according to the nature of the conveying materials, conveying capacity, conveying distance, conveying height, etc.

2 The conveying capacity of the conveying equipment should be higher than the actual maximum conveying capacity, and the excess capacity of the conveying capacity should be determined according to the fluctuation of different conveying equipment and incoming materials;

3 The transfer point of the conveying equipment should be set according to the nature of the conveying material. The cutting slip should reduce the drop, and the material of the granular material should have anti-wearing and noise reduction measures.

Ninth, the process design of special areas should meet the following requirements:

1 In the construction of high-altitude areas, the selection of equipment such as rotary kiln, preheater, burner, drying mill, dryer, cooler, fan and air compressor should be corrected according to altitude;

2 The motor should meet the requirements of high altitude when ordering;

3 It is advisable to expand the thermal insulation range in the construction of cold areas, and take anti-freezing measures to ensure the smooth flow of gas, oil and water in production.

The raw materials of the main components of the cement plant production line shall comply with the relevant provisions of the current industry standard “metallurgy, chemical limestone, dolomite, geological exploration specifications for cement raw materials mines” DZ / T 0213, and comprehensive utilization according to the conditions of the deposit and the quality characteristics of the deposit. Mineral resources. Product plans and raw material varieties should be comprehensively determined based on factors such as raw materials, fuel quality, reserves and process performance testing of raw materials.

The raw materials of the main components should be used together with low-grade raw materials and industrial wastes or as an alternative raw material, and the technical feasibility and economic rationality of the scheme should be determined through the raw material process performance test.

First, raw materials

1. Calcium raw materials should meet the following requirements:

(1) The main quality indicators of calcium raw materials should meet the requirements of the following table.

Raw material composition Content index
Calcium oxide (CaO) > 48%
Magnesium oxide (MgO) <3%
Base (Na 2 O + of K 2 O) <0.6%
Sulfur trioxide (SO 3) <0.5%
Free silicon oxide (F-SiO 2 ) <8%(quartz)Or <4% (Meteorite)
Chloride (chloride ion) <0.03%
Phosphorus pentoxide (P2O5) <0.08%

(2) When the product content requires a limited amount of magnesium oxide (MgO) or alkali (K2O 10 Na2O), the quality requirements of magnesium oxide (MgO) or alkali (K2O 10 Na2O) should be changed accordingly.

(3) Where conditions permit, the rock materials such as interlayers, surrounding rocks and overburdens present in the mining area shall be reasonably combined for comprehensive utilization.

(4) When the fractured soil in the sediment, the chemical composition of the loose material such as karst filling and covering soil is suitable, it should be properly mixed and mixed under the premise of satisfying the raw material of the cement raw material.

2. Silicon-aluminum materials should meet the following requirements:

(1) The main quality indicators of silicon-aluminum raw materials should meet the requirements of the following table.

Material ingredients index
silicic acid rate SM 3~4
aluminum oxygen rate AM 1.5~3
Magnesium (MgO) Content <3%
base (K 2 O Na 2 O +) Content <4%
sulphur trioxide (SO 3) Content <1%
chloride (chloride) Content <0.03%
P2O5) Content <0.8%

(2) When the product formulation requires a limited amount of magnesium oxide (MgO) or alkali (K2O 10 Na2O), the quality requirements of magnesium oxide MgO or alkali (K2O 10 Na2O) in the table should be changed accordingly.

(3) Rock silica-alumina raw materials should be used preferentially where resource conditions permit.

3. The main quality indicators of iron modified raw materials should meet the following requirements:

The content of Fe2O3) of (1) is preferably greater than 40.00%;

(2) The content of magnesium oxide (MgO) should be less than 3.00%;

(3) The content of the base (Na 2 O 10 of K 2 O) should be less than 2.00%.

4. The main quality indicators of siliceous calibration materials should meet the following requirements:

(1) the content of silica (silica) is preferably greater than 80%, or the ratio of silicic acid SM is preferably greater than 4;

(2) the content of magnesium oxide (MgO) is preferably less than 3%;

(3) The alkali (K2O + Na2O) content should be less than 2%.

5. The main quality indicators of aluminum calibration raw materials should meet the following requirements:
1 The content of alumina (Al2O3) is preferably greater than 25%;

2 The content of magnesium oxide (MgO) should be less than 3.00%;

3 alkali (K2O + Na2O) content should be less than 2.00%.

Second, fuel

1. For coal used for calcination, coal with appropriate ash content, sulfur content, volatile matter and calorific value should be selected.

2. The quality requirements for calcined coal should meet the requirements of the following table.

serial number name symbol index
1 ash Ade ≤28%
2 volatile substances VAD ≤35%
3 Sulfur content S1,Ads ≤2%
4 low calorific value QNET, Advertising ≥23000kJ/kg
five moisture metric tons ≤15%
6 internal water mad ≤3%

3. Quality requirements for natural gas and heavy oil for general calcination

gasoline name symbol index
natural gas low calorific value QNET ≥23000kJ/ m3 (standard state)
heavy oil low calorific value QNET ≥38000kJ/kg
sulfur content Saint ≤4%

4. The choice of coagulant should meet the following requirements:

(1) Gypsum can be used alone, and anhydrite can be used alone or mixed with gypsum after confirmation test;

(2) When using industrial by-product gypsum, tests should be carried out to prove that industrial by-product gypsum has no adverse effect on cement performance.

5. Mixed materials

(1) The choice of mixed materials should be determined according to the chemical composition and performance requirements of cement products; the source of mixed materials and mixed materials should be selected according to clinker quality, mixed material quality, mixed material price and transportation conditions; Mix the amount to meet the quality requirements of the cement.

(2) The active mixed materials, inactive mixed materials and kiln dust shall comply with the relevant provisions of the current national standard “Ordinary Portland Cement” GB 175. The addition of other special cement mixed materials should meet the requirements of national standards. For the corresponding cement variety.

(3) The determination of other types of mixed materials in composite Portland cement shall comply with the relevant provisions of the current national standard “Test method for industrial waste residue activity of cement mixture” CB / T12957.

Third, raw materials, fuel process performance test

1. Raw material and fuel processing performance tests shall be carried out in laboratory scale tests. New raw material varieties and industrial wastes should also be tested on a semi-industrial scale;

2. The main design unit shall submit formal sampling requirements according to the raw material resource conditions and production methods. Sampling requirements should include sample type, quality requirements and sample weight;

3. The sample should be fully representative. In the raw material and fuel processing performance test items, tests for burnout characteristics, grindability, abrasion, grindability, flammability and volatility should be included. When using bar grinding, it is recommended to wear the model. Sex and grindability test; plastic index test should be carried out on wet grass.

4. The test project should be selected according to the production characteristics and process requirements of the cement plant, and should meet the following requirements:

(1) When selecting and designing the coal mill, the determination of the grindability index of raw coal should be in accordance with the relevant provisions of the current national standard “Method for Determination of Grindability Index of Coal”. “Refractory Method” GB / T 2565;

(2) In the raw material grinding process, mill selection and other process design, the grinding work index of the raw material and raw material mixture or the grindability index of the spoke mill material should be determined according to the current national standards. Test method for easy grinding of cement raw materials (Bondi method) “GB / T 26567 relevant provisions;

(3) When designing the raw material batching scheme and determining the raw material fineness and clinker rate value, the judgment of the flammability performance of the cement raw material should be in accordance with the current national standard “cement burning performance test method” raw material “GB/T 26566”.

In order to make the cement factory production line in the design, it can meet the requirements of energy saving, environmental protection and safety. The selection and planning of the cement factory site should rely on social resources and cooperate with other industries or enterprises according to regional conditions to reduce project investment and improve labor productivity. Reasonably determine the construction period.

First, site selection

1 The site selection should meet the requirements of industrial layout and regional construction planning, and should be carried out in accordance with the relevant provisions of the preliminary work.

2 The site selection should be based on the construction scale, source of raw materials, transportation, power supply and water supply, engineering geology, environmental protection, enterprise cooperation conditions, existing facilities of the site and market flow of products, etc. Comprehensively determined.

3 The site should be located near the limestone mine and should have economic and reasonable transportation conditions. It should be conducive to the cooperation with neighboring cities and towns. It is not appropriate to locate the site in areas far from towns and cities with inconvenient transportation.

4 The site should meet the power supply and water source required for continuous production requirements and development planning. The transmission and water transportation routes outside the plant should be short-lived and should be easy to maintain and manage.

5 The site should be developed according to the requirements of the enterprise’s long-term planning, while meeting the site area required in the near future and not increasing the construction cost.

6 The site should have engineering geological and hydrogeological conditions that meet the requirements of the project construction, and should avoid useful mineral deposits.

7 The site should be located on the upwind side of the minimum frequency wind direction in towns and residential areas throughout the year, and should not be selected in the windy section.

8 The elevation of the site should be higher than the flood level of the flood control standard plus 0.5m. When the requirements are not met, the plant area shall be equipped with flood control facilities and shall be completed once in the initial project. When the factory is located in the inner area and there is a drainage facility, the elevation of the site should be the designed water level plus 0.5m. When the plant is located in a mountainous area, flood control and flood discharge facilities should be installed.

9 The flood control standards of cement plants should meet the requirements of the following table.

level Factory scale Flood control standard [recurrence period (year)]
Extra large 50~100
Large 50~100
Medium 50
Small 25~50

Note: The factories of multiple production lines have correspondingly improved flood control standards.

10 External transportation conditions and transportation methods such as bridges and culverts, tunnels, vehicles, terminals, etc. shall meet the requirements for large or oversized equipment.

Second, the master plan

1 The overall plan should meet the requirements of regional planning or urban and rural planning. It is advisable to cooperate with urban residential areas and neighboring industrial enterprises in environmental protection, transportation, power utilities, repair, warehousing, culture and education, and living facilities.

2 The master plan should handle the relationship between the near future and the long term. The planning should be centralized in the near future, and the development space should be reserved for the long-term planning.

3 The layout of the plant should be reasonable, and should deal with the plant area and limestone mine, silicon-aluminum raw material mine, water source, water supply treatment plant, sewage treatment plant, total anti-pressure substation, railway junction station, off-site railway and water terminal, etc. The relationship should also leave room for the development of collaborative waste disposal.

4 External transportation of cement plants shall comply with the following requirements:

(1) The mode of transportation outside the factory shall be determined according to the local transportation conditions.

(2) The proportion of bulk cement should be increased in various modes of transportation.

(3) The direction of the railway connection point and the line entering the factory should be closely coordinated with the layout and vertical design of the plant area, and determined after technical and economic comparison.

5 Newly built Class III and IV railways should be directly transported with the road network railway, and no transfer station should be set up. When the existing railways, special railways and railway special lines are rebuilt and expanded, the transfer stations should be phased out.

6 The connection between the road outside the factory and the roads in the town and residential area should be smooth and short. There should be convenient road links between the plant area and railway stations, terminals, water sources, mining industrial sites and adjacent cooperative enterprises.

7 The layout of public facilities outside the factory shall comply with the following provisions:

(1) The terminal tower of the incoming line should be set near the load center of the factory, and the entry and exit line should be convenient, and the discharge point of the pollution source should be avoided. It should be located on the windward side of the dust pollution source;

(2) The source of water from rivers and rivers should be located upstream of the river, and the shoreline is stable without obstructing the navigational section, and should meet the requirements of river regulation planning;

(3) The high level pool should be installed in a section that will not cause landslide or collapse due to leakage overflow;

(4) The sewage treatment and discharge arranged along the river and the bank should be located downstream of the river, and should meet the environmental protection requirements, and should be on the upwind side of the annual minimum frequency wind direction;

(5) The boiler room for central heating should be placed near the heat load center, and should be on the upwind side of the annual minimum frequency wind direction, and should have convenient coal storage storage site and slag discharge conditions.

Third, land use planning

1 The site selection should use wasteland, inferior land, hillside land, and should not occupy cultivated land.

2 Plant layout should use the terrain height difference to reasonably set the platform. Under the premise of meeting the process flow, the internal material transportation distance should be shortened and the factory floor space should be reduced.

3 The construction factor of the new cement plant should not be less than 30%. The land area of ​​the administrative and living service facilities in the factory shall not exceed 7% of the total land used for the project.

4 The design scale and daily volume of the cement factory production line should be in accordance with the following table.

Scale type Daily output W( t/ d)
Extra large W≥7000
Large 4000≥W<7000
Medium 2000≥W < 4000
Small W<2000

Fourth, assessment and report

1 agree with the idea of ​​land acquisition and site selection, including the area of ​​land used, the nature and type of land;

2 Agree to the documents selected for the project site;

3 Mining license documents approved by the limestone resource exploration report;

4 Environmental impact assessment report and approval documents;

5 Engineering geological survey report of the site;

6 Raw material and fuel process performance test report;

7 Hydrogeological and engineering geological exploration report of water source, topographic map of water source and water transmission line: 2000 : 1000, or water supply letter of intent (or agreement);

8 agree to the opinion of the power supply and the initial power supply plan;

9 Regional topographic map 1: 10000; 1: 50000 or 1: 5000;

10 Topographic map of the plant area and mining area includes feasibility study, preliminary design stage 1:2000 or 1:1000, construction drawing design stage 1:1000 or 1:500;

11 Topographic map of railway dedicated line 1: 2000 or 1: 1000;

12 Meteorological and hydrological data (including flood data of the plant area) in the construction area;

13 Earthquake fortification intensity data;

14 Approved safety assessment report;

15 Sewage discharge letter of intent or agreement;

16 Approved geological hazard assessment report, soil and water conservation plan evaluation report and restoration ecological evaluation report;

17 Approved Energy Conservation Assessment Report.

In recent years, the cement industry has tended to be saturated, and the country’s requirements for energy conservation and environmental protection gradually become higher. Considering various factors, all cement plants constantly carrying out the upgrading works. The complexity of the new dry process management is the non-reproducibility, even use the same design and drawings, the adjacent two production lines may have a great difference in production quality, consumption and so on, due to the construction of refractory , adjustment of coal injection pipe, process operation level, and etc. In order to reduce the production cost of cement clinker, the most effective way is to increase the output of cement clinker, reduce fuel consumption and electricity, it is necessary to find out the bottleneck and improve it. The following introduction give us a direction to improve the production.

 

  • Raw material grinding system

  1. Reduce the particle size and moisture content of the grinding material;
  2. The modification of internal structure of the classifier, to improve the efficiency of powder separation;
  3. Improve the three way valves at vertical mill feed, to reduce air leakage;
  4. Optimization of nozzle ring and retaining ring;

Vertical-mill

  • Clinker calcining system

  1. Optimize and stabilize raw meal composition and improve the stability of feed volume;
  2. Adjust the ventilation section area of the preheater
  3. Increase the furnace capacity of the calciner, and modify the cyclone and connecting air pipes at various stage accordingly.
  4. Raise kiln speed, thin material and burn quickly.

Preheater

  • Cooling system

  1. Adjust the air distribution of the grate cooler and increase the secondary and tertiary air temperature.

Cooler

  • Cement mill system

  1. Improving the roller press, the fine powder rate can be increased.
  2. Modify the structure of the classifier, the efficiency of classifier could be raised 15% – 30%.
  3. Modify the internal structure of V classifier, the aggregate phenomenon is eliminated.
  4. Modify the internal partition plate of the mill, the empty area is reduced and the grinding efficiency is improved

Ball-mill

The above measures are only part of the improvement of cement plant, according to the different conditions of each cement plant, the measures taken are also different. Luoyang Building Materials Architectural Design and Research Institute specializes in the design and research of cement industry, and has accumulated a lot of experience and technology in recent years, constantly developing new solutions, if necessary, please contact our institute.

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