Against the backdrop of the cement and building materials industry accelerating its upgrade towards green energy saving, intelligent efficiency, and intensive and stable production, cement grinding stations, as the core terminal link in finished cement production, have their process design, equipment configuration, and system stability directly determining the overall production line's capacity efficiency, finished product quality, and environmental protection level.
Jiangsu Pengfei Group has been deeply involved in the building materials equipment industry for four decades. It possesses a mature R&D system and production bases for main equipment such as rotary kilns, ball mills, vertical roller mills, and roller presses. With extensive domestic and international engineering and construction experience, it specializes in EPC (Engineering, Procurement, and Construction) projects for cement grinding stations with an annual capacity of 200,000 to 2 million tons . The group boasts a full-chain, one-stop EPC capability, encompassing project planning, process design, complete equipment manufacturing, civil construction, installation and commissioning, technical training, production ramp-up, and maintenance. It can customize energy-saving, intelligent, and green overall solutions for grinding projects with different capacities, creating high-cost-effectiveness, high stability, and high return rate modern grinding station projects for global building materials clients.
Pengfei Ball Mill Production Workshop
Pengfei Vertical Mill
Pengfei Roller Press
Part I
Core process flow: intelligent and efficient grinding for quality improvement and cost reduction
Core process flow
The cement grinding stations constructed by Pengfei Group primarily employ two mature and energy-saving process routes: combined grinding with roller press and ball mill, and final grinding with vertical roller mill. These routes are suitable for a full range of production capacities from 200,000 to 2 million tons, featuring high automation, low energy consumption, minimal dust generation, and stable finished product quality. The entire process is closed-loop controllable and highly efficient. The complete process flow is as follows:
1. Raw material ratio and pretreatment
Raw materials such as clinker, gypsum, slag, and fly ash are screened and crushed before entering the batching system. The system automatically and accurately proportions the materials according to the production requirements of different grades of cement, eliminating human error and ensuring that the strength, fineness, and stability of the finished product are uniform and stable.
2. Closed conveying and pre-grinding extrusion
The proportioned materials are fed steadily into the conveying equipment and pre-compressed and crushed by a high-pressure roller press to crush, loosen, and refine the lumpy materials, which greatly reduces the grinding load of the subsequent ball mill and increases the system's hourly output and reduces unit power consumption from the source.
3. Fine grinding of the main unit
The pre-ground material is fed into a ball mill or vertical mill main unit, where it is ground with steel balls and crushed by grinding rollers to achieve ultrafine processing, complete powder shaping and particle size optimization, and meet the fineness and specific surface area standards of high-grade cement and ordinary cement.
4. Efficient powder selection and circulating grinding
The grinding material is carried by the airflow into the high-efficiency classifier for precise classification. Qualified fine powder enters the finished product collection process, while unqualified coarse powder is automatically returned to the mill for re-grinding, forming a closed-loop circulating grinding system that maximizes raw material utilization, eliminates waste, and improves the finished product qualification rate.
5. Finished product dust collection, storage, and environmental compliance.
Qualified finished products are collected centrally by a high-efficiency baghouse dust collection system and transported to the finished product warehouse for storage. They can be freely discharged from bulk and packaging equipment. The entire production line operates in a completely enclosed manner, equipped with a complete dust removal system. Dust emissions are better than national standards and fully comply with the requirements of green factories and dual-carbon energy-saving production.
The Anhui Wanwei Group's 2 million-ton-per-year grinding station technical upgrade project, undertaken by Jiangsu Pengfei Group as an EPC general contractor, utilizes a combined grinding system consisting of a PFG180-140 large roller press and a Φ4.2×13m cement mill.
Part II
Core equipment configuration, dual systems adapted to full production capacity requirements
Core equipment configuration
Pengfei Group's grinding stations rely on two mainstream mature process configurations, and can be flexibly selected according to the customer's production capacity, material characteristics, and site conditions, taking into account both investment costs and long-term operating benefits.
1. Combined grinding system of roller press and ball mill
With the most universal and mature configuration in the industry, relying on the combined advantages of "roll pre-crushing + ball milling for fine grinding", it significantly increases production and reduces consumption compared to the traditional single ball milling process. It has a low equipment failure rate, is easy to maintain, and has a high cost performance, making it suitable for most large, medium and small-scale cement grinding production lines.
2. Vertical roller mill final grinding system
It integrates drying, grinding, grading and conveying, with a short process flow, small footprint and high degree of automation. It has excellent drying capacity and is especially suitable for grinding high-moisture mixed materials such as slag and fly ash. It has outstanding energy-saving effect and is environmentally friendly, making it the preferred solution for modern intelligent grinding stations.
Pengfei's pre-powder vertical mill and ball mill are being used at the Shuyang Yihuai Group, one of the first batch of energy-saving cement grinding demonstration production lines in Jiangsu Province with an annual output of 1.2 million tons.
Part III
A tiered equipment mix, covering full production capacity from 200,000 to 2 million tons.
Gradient equipment combination
Relying on Pengfei's independently developed and manufactured Φ3.2m, Φ3.8m, and Φ4.2m series large ball mills, matching high-pressure roller presses, and a full series of vertical roller mills, it can accurately match various production capacities ranging from 200,000 tons to 2 million tons per year. The standardized complete set configuration allows for immediate installation and commissioning, ensuring stable and efficient production.
1. Φ3.2m ball mill supporting scheme | annual output of 200,000 to 600,000 tons
Targeting small and medium-sized grinding station projects, it emphasizes low investment, quick commissioning, and low operation and maintenance, making it suitable for small building materials enterprises in the region and supporting building materials production lines in towns and villages.
Core complete set of configuration: Φ3.2×13m ball mill, matched with a small high-pressure roller press, V-type powder concentrator, and fully automatic batching and central control system.
This configuration has a small footprint, short installation period, low energy consumption, and stable and reliable operation, fully meeting the normal production needs of 200,000 to 600,000 tons. It is the preferred high-performance and cost-effective solution for small grinding stations.
2. Φ3.8m ball mill supporting scheme | annual output of 800,000-1,200,000 tons
It features mainstream medium-sized standardized configurations that balance capacity, efficiency, and stability, and has been implemented in the most projects with the strongest adaptability.
Core complete set of configuration: Φ3.8×13m ball mill, medium-sized high-pressure roller press, O-SEPA high-efficiency powder concentrator, and intelligent centralized control system.
The system has strong compatibility, can flexibly adjust the ratio of mixed materials, has uniform and controllable finished product quality, supports continuous production around the clock, and is perfectly suited for medium-scale grinding projects with a capacity of 800,000 to 1.2 million tons.
3. Φ4.2m ball mill supporting scheme | annual output of 1.5-2 million tons
High-yield configurations are customized for large-scale intelligent grinding stations, featuring large-scale, high-load, ultra-stable production, and low unit consumption.
Core complete set of configuration: Φ4.2×13m large ball mill, large high-pressure roller press, high-airflow and high-efficiency powder concentrator, and complete intelligent central control automation system.
The equipment has a strong load-bearing capacity and can operate continuously at full load for 24 hours. Its energy consumption and output indicators are better than industry standards, making it the benchmark configuration for large-scale cement grinding stations with a capacity of 2 million tons in China.
4. Complete series of vertical roller mill supporting solutions | Universal 200,000-2,000,000 tons
Pengfei Group's vertical mill equipment can independently form a final powder grinding production line. Depending on customer capacity requirements, it can be used in single-machine or multi-machine parallel operation, flexibly covering all capacity ranges from 200,000 to 2 million tons. The process is simple, with strong drying capacity, energy saving and environmental protection, and a high degree of automation, making it suitable for green factory and smart factory construction standards.
Pengfei constructed the 1 million-ton-per-year cement grinding station for Shandong Shunxing Cement Co., Ltd.
Part IV
A wealth of exemplary cases demonstrate our engineering capabilities.
A vast collection of typical cases
Pengfei Group has deep roots in the domestic and international building materials markets, delivering hundreds of EPC general contracting projects for cement grinding stations ranging from 200,000 to 2 million tons. It has accumulated rich experience in site planning, process optimization, equipment integration, on-site construction, and production and operation maintenance, resulting in a solid reputation for successful project implementation.
Domestic projects are located in major building material production areas across the country, including Jiangsu, Shandong, Anhui, Henan, Hubei, and Southwest China. From small-scale 200,000-ton demonstration lines and medium-sized million-ton production lines to large-scale 2 million-ton intelligent grinding stations, all have been successfully commissioned, reached full production capacity, and have been operating stably for a long time.
Our overseas projects have been exported to many countries in Central Asia and Africa. Relying on standardized construction, normalized management, and localized services, we have successfully completed many overseas EPC projects. With our excellent Chinese equipment, Chinese craftsmanship, and Chinese service, we have helped upgrade the global building materials industry.
All implemented projects have achieved their construction goals of meeting production capacity targets, maintaining stable quality, controlling energy consumption, and complying with environmental regulations, becoming high-quality benchmarks for cement grinding projects in the region.
Pengfei Group's 800,000-ton/year cement grinding station EP project in Türkiye's KYS has been put into operation.
Chaohu Hengxin selected a Pengfei ф3.8x13m tube mill + ф1.8x1.2m roller press to form a double-circulation semi-finished grinding system.
It has become a model for energy conservation and emission reduction in the national cement industry through joint grinding. The overall grinding power consumption is as low as 19 kWh/t.
The machine produces PO52.5 cement with an hourly output of 210 t/h and a comprehensive grinding power consumption as low as 27.6 kWh/t.
Part V
We provide end-to-end turnkey services, empowering project implementation throughout the entire process.
Full-chain one-stop turnkey service
Pengfei focuses on providing one-stop EPC general contracting services throughout the entire lifecycle, ensuring projects are fully supported from commencement to stable production and profitability, saving clients time, effort, and worry.
1. Customized solution + original complete equipment
Based on the customer's site, production capacity, budget, and environmental protection policy, we provide one-on-one optimization of process solutions and scientific selection and configuration. All grinding machines, roller presses, vertical roller mills, powder concentrators, conveyors, and dust collecting equipment are original factory-developed and self-produced, ensuring controllable quality, universal parts, and comprehensive after-sales support.
2. Standardized installation + professional technical training
Our professional installation team strictly adheres to specifications during construction, ensuring high-quality work and timely completion. After project completion, we provide systematic technical training to operators, teaching them equipment operation, routine maintenance, parameter adjustment, and troubleshooting, empowering customers to independently manage production and maintenance.
3. Install and conduct trial production to ensure that production reaches the designed capacity and meets the standards.
We provide full-process monitoring of trial production, debugging, and feeding operation, precisely optimize process parameters, quickly achieve full-load production, and ensure that all indicators such as output, fineness, strength, and energy consumption meet the standards and are output stably, so as to quickly realize the return on investment and profitability.
4. Long-term on-site production maintenance and continuous after-sales support.
We establish exclusive project service archives to provide production support services such as long-term inspections, equipment maintenance, emergency repairs, parts supply, and process optimization. We offer rapid, 24/7 response to completely eliminate concerns about production line operation and ensure long-term, efficient, and stable production at the grinding station.
Pengfei Group's EPC (Engineering, Procurement, and Construction) project for a 1.6 million-ton-per-year grinding station in Bangladesh.
From 200,000-ton to 2 million-ton intelligent high-quality grinding stations, Jiangsu Pengfei Group comprehensively covers the construction needs of various cement grinding projects with 40 years of craftsmanship, professional technology, standardized engineering quality, and full-chain turnkey services.
Building a solid foundation with quality, winning the market with technology, and creating a reputation through service, Pengfei Group continuously strives to create benchmark projects of modern cement grinding that are green, efficient, intelligent, and stable in production for domestic and international clients, contributing to the high-quality and sustainable development of the building materials industry!
Join hands with Pengfei to build a high-standard, high-productivity, and high-return cement grinding station!
