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1500t/d cement rotary kiln production line project

 

1500t/d cement rotary kiln production line project

 

                                      

1.Production scale, production method and cement types
1.1 Production method
The production method is dry process. A rotary kiln(φ3.5*54m) production line with five-stage cyclone pre-heater and decomposition furnace will be adopted.
Production scale and capacity
The production capacity is 1500t/d for clinker, while 500,000t/a for Portland cement when mixed with gypsum.
1.3  Cement types
The technology and equipment adopted can produce 32.5MP and 42.5MP types of cement in accordance with Chinese Standard GB175-1999. They can be adjusted according to market demand.
2.1.Raw materials properties chemical composition
 
Name
L.O.I
SiO2
Al2O3
Fe2O3
CaO
Mgo
K2O
Na2O
SO3
Cl-
Water content
Density t/m3
Limestone
39.27
7.17
2.93
1.25
46.94
1.03
0.13
0.23
 
0.009
0.45
 
Shale
21.89
36.14
10.39
3.27
22.03
0.8
0.99
0.33
 
0.015
0.46
 
Silica
0.10
95.5
1.00
0.20
0.90
0.50
 
 
 
 
 
 
Gypsum
 
1.40
0.60
0.20
30.52
0.05
0.10
0.10
47.10
 
18.70
 
iron
11.5
30.56
22.12
26.91
1.12
 
 
 
 
 
 
 
The technical property of mazut:Min. value is ≥9000 kcal/kg(37620kJ/kg)
     The S content of mazut:   2.5    %.
According to raw material and fuel conditions, the following materials will be used for material blending: limestone, Silica, and iron powder.

Proportional ratio of raw material(%)
Limestone
clay
Sand
iron
89.00
0
9.45
4.2

LOSS
SiO2
Al2O3
Fe2O3
CaO
MgO
K2O+N2O
 SO3
Cl-
35.440
14.159
3.505
2.056
41.885
0.950
0.018
0.033
0.049
 
21.311
5.225
3.196
63.041
1.430
 
 
 

C3S
C2S
C3A
C4AF
53.42
20.79
8.62
10.32

This production line adopts advanced technology and equipment in 1990s to raise technical level and to ensure design indexes. New five-stage cyclone pre-heater system, high efficiency air girder grate cooler, multi-passage pulverized coal burner, Davison heat temperature fan, Luqi BS930 electrical dust collector, as well as chain-board elevator, chain conveyor adopted in this production line can ensure that the technology is advanced compared to other production lines with the same scale.
If it has not bad influences on completeness,continuity and reliability, process procedures will be simplified to enhance production management, reduce troubles and lower investment. 
Top of silos are without covers, heat temperature fan and dust collectors are open arranged and glass fiber rainproof covers instead of roofs will be set for belt conveyor passages. There will be no building for bucket elevator.
If it has not bad influences on normal production, by properly reducing storage periods for all raw materials, semi-product and finished product and adopting shed to store those materials and products, civil engineering costs will be greatly reduced.
Frame for pre-heater at kiln inlet will adopt steel structure to save investment, accelerate erection speed and beautify building. 
3.4 Measures have been taken to save energy and reduce consumption. using chain-board elevator and air slides, reliability of the system is enhanced and conveying energy consumption is decreased.     
3.5 All necessary parts will adopt measuring equipment to guarantee scientific management. For example, there are measuring equipment at those parts such as raw meal blending, raw materials entering into plant, raw meal feeding to kiln, pulverized coal feeding to kiln, clinker outgoing kiln and clinker outgoing silos.  
3.6 Effective measures have been taken to guarantee strict environment protection standards. Different efficient dust collectors are set at all dust producing points according to different characteristics of waste gas.
4.Technical plan
4.1 Production process
4.1.1 Production scale, production method and product plan
kiln(φ3.5×54m) will be used as burning equipment.  Five-stage cyclone pre-heater and decomposition furnace will be adopted at kiln inlet.
4.1.2 Selection of main equipment and production facilities
4.1.2.1 Limestone crushing
Single-stage hammer crusher is used for limestone crushing. This type of crusher is suitable in crushing medium strength ore such as limestone, marlite, slag, gypsum and coal. It can crush big ore to required size. Moreover, it can crush ore which has moisture and earth in it because it adopts discharging grates in the same direction. It has special iron feeding protection device, which can rebound the uncrushed metals to the feeder, so the operator can stop it if he hears peculiar sound to deal with this matter.     
Limestone crushing will adopt TKPC16.18 single-stage hammer crusher adopted. Feeding size is 800mm, production capacity is  380t/h and annual usage rate is25.51%.
4.1.2.2 Raw meal grinding
For 1500t/d cement production line, available raw mill system is HRM2800m mill system.
4.1.2.3 Raw meal homogenizing and storage
φ15×50mMF silo both can homogenize and store raw meal will be adopted. Its capacity is 6500t and storage period is 2.86days.
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