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Cement Production Line Rotary Four From 800 to 6000tpd for Afrique Plant¹

Building Material Making Machinery Cement Making Machine Cement Production Line Rotary Four Cement Turnkey Plant

Jiangsu Pengfei Group Co., Ltd.

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Product Description New Type Dry Process Cement Production LineDescription of New Type Dry Process Cement Production Line:This new type dry process cement production line is a kind of process mainly used for small, medium and large-scale cement plants. Its preheater employs outside kiln precalciner. Capable of utilizing the waste heat from kiln inlet to decompose raw meal, this line is good at saving electricity and heat. Its closed production line makes it possible to reduce its ambient dust pollution to less than 50mg/Nm3. Besides, its capacity to make use waste heat makes it quite cost efficient for users.Here in Jiangsu Pengfei Group Co., Ltd, we offer one-stop service for you, including designing, building, suitable equipment providing, installing and debugging, technical serving, and overall contracting. And we have successfully finished the construction of cement production lines of 6000t/d, 5000t/d, 3000t/d, 2500t/d, 1500t/d, and 600t/d.Production Flow of New Type Dry Process Cement Production Line:1. Crushing and Pre-homogenizing:Most of the raw materials, like limestone, clay, iron ores, and coal, should be crushed before their pre-homogenization. Limestone is the primary material in this line, and due to its large particle size and high hardness, its good crushing plays an important role in the whole line. Special stacking and reclaiming technology has been used in the pre-homogenizing process so that raw materials can be better primarily homogenized.2. Raw Meal Preparing:Since the raw meal grinding work takes up more than 30% labor force in the whole dry process cement production line, it is quite important to choose appropriate grinding equipment and technological process so that high-quality products can be obtained.3. Raw Meal Homogenizing:The raw meal homogenization is a key factor for stable clinker calcination.4. Preheating and Decomposing:The preheater is used to preheat as well as decompose raw meal. So the length of the rotary kiln is effectively shortened. And the raw meal can fully exchange heat with the hot gases from the kiln. Because of its rapid and high-efficiency heat transfer, the production efficiency and heat consumption of this production line are greatly improved.5. Clinker Calcining:After its preheating and pre-decomposing, the raw meal will be calcined in the rotary kiln, where the generated carbonate will be further decomposed. Meanwhile, a series of solid phase reactions will take place.6. Cement Grinding:As the last process, the cement grinding will consume a great deal of electricity. And in this process, special size granule cement will be obtained.7. Cement Packaging:The cement can be transported in bulk or in bags.Delivery, assembly, erection and putting in operation of a complete cement productionPlant with a capacity of 600- 6000 ton clinker per day.Main equipments like kiln, preheater, mills, roller press, dust collector, crusher, cooler will be produced in factories of Pengfei. Other equipments like electric equipments, motor and gear box will be purchased from Chinese best suppliers, including SIEMENS, FLENDER, S-E-W Chinese branch.Design and layout of the plant is for production of Portland cement, Type 42.5 R/N.The dry process is very well known and can be inspected and controlled in many production plants erected by Pengfei.The complete equipment, devices and accessories can be inspected and controlled on site/location of manufacturer before loading.Scope of delivery and service:- Feasibility study (development of cement quantity ratios and analysis of raw materials) if you need.- Creating of basic engineering- Creating of construction (as-built documentation)- Delivery of the complete plant equipment- Delivery of automation system- Delivery of electrical kits- Delivery of Lab and test engineering station for permanent quality monitoring- Erection the entire plant on the prepared foundations.- Taking in function (set and run up) of the entire plant.- Training of customer's operating staff- Hand over operating manuals and trouble shooting guide line- One year full replacement warranty. -Sales MR 0086 182605673682500 Tons/Day Dry Process Cement PlantProcess Flow of 2500Tons/Day Dry Process Cement Plant:The main process flow of this 2500t/d dry process cement plant is as follows:1. Crushing, Conveying and Storing of Limestone.First, limestone is crushed by the MB56/75 crusher. When the maximum feeding size is not more than 1500mm and the discharging size is not more than 75mm, the crushing capacity of this machine is 500 to 600t/h.Second, the crushed limestone will be transported by belt conveyor to the Φ80m round prehomogenization yard whose storage capacity is 34100t.Third, the crushed limestone will be prehomogenized and then stored in this yard. Additionally, the stacking capacity of our stacker is 800t/h, and the reclaiming capacity of reclaimer is 500t/h.Finally, the prehomogenized limestone will be sent to the batching station for raw materials.2. Storing, Crushing and Conveying of Auxiliary Raw Materials.The open storage yard for sandstones has a specification of 60 m×20m, and a storage capacity of 5100t. And the open storage yard for iron ores has a specification of 32 m×20m, and a storage capacity of 2730 t.PC1609 hammer crusher is used to crush both sandstones and iron ores. When the feeding size is not more than 600mm, and discharging size less than 25mm, its crushing capacity is 50 to 70t/h.The crushed sandstones and iron ores will be sent by the belt conveyor to batching warehouse for storage.The pulverized coal will be stored in the batching warehouse for storage through the self-discharging system.3. Batching Station for Raw Materials.In the batching station, there are four batching warehouses respectively for limestone, sandstones, iron ores, and pulverized coal, and their specifications are φ12 m×25m, and storage capacity are 2200t,1600t, 2200t, and 770t respectively. Inside these warehouses, there are weighing feeders used to measure materials to be given.4. Grinding of Raw Materials and Waste Gases Treating.MLS3626 vertical mill is used to grind raw materials, and waste gases from preheater are applied in drying. The whole production capacity is 185t/h.Grinded raw meal is separated by the fine powder separator, and then mixed with powder in the conditioning tower and electric environmental protection equipment. Finally it will be sent to the homogenizing warehouse for homogenization as well as storage.Waste gases from the mill will take purification treatment in the electric environmental protection equipment before discharged into the air.5. Homogenizing of Raw Meal.Our CP homogenizing silo has a specification of Φ18m×50m, and its effective storage capacity is 9000t.6. Calcining and Storing of Clinker.The specification of our RF5/2500 decomposition furnace isΦ4.0×60m, and our round 2-φ18×40m warehouse has an effective storage capacity of 2-10000t. Additionally, the final discharging gas has a dust content less than 100mg/m3 if in standard conditions.7. Storing and Conveying of Raw Coal and Pulverized Coal.Raw coal will be stored and prehomogenized in a crane room with a specification of 21m×113m and a storage capacity of 9300t. There are two raw coal silos in the crane room, and weighing feeder can also be found in that room. A MPF1713 coal grinder is used to grind coal. When the moisture of feeding materials is no more than 10%, the moisture of pulverized coal is no more than 1%, and the particle size of raw meal is no more than 50mm, the output of the whole system is 20t/h.The pulverized coal will be sent to two silos for storage, and the purified waste gas is discharged into the atmosphere. There is also measuring system in these two silos.8. Drying and Conveying of Slag and Crushing and Conveying of Gypsum.The drying capacity of ourφ2.4×18.350m dryer is more than 30t/h, and the open storage area has a storage capacity of 4000t. When the feeding size is no more than 600mm and the discharging size is no more than 25mm, the productivity of our PFC-1609 impact hammer crusher is 50 to 70t/h.9. Grinding, Conveying and Storing of Cement.In the cement batching station, there are four batching rooms respectively for clinker, gypsum, limestone and slag. And the clinker one has a specification of φ10 m×22m and a storage capacity of 2000t. The specification of batching rooms of gypsum, slag and limestone is φ8 m×22m, and their storage capacity is 800t, 400t and 900t respectively. The packaging capacity of packing machine is 90t/h.The delivery does include:- Delivery and transport from the customer's harbour to the erecting place if you want- Civil work- Any building work- Grounding work- Entire steel frame work- Lightning protection Scope of erection:- Erecting of the entire plant equipment by an experienced erecting team of Pengfei.- The erection will be done only in a safe country. In case of erecting in an insecure country like IRAN or Central African State etc. are higher costs considered as agreed.- Therefore has to be a separate installment plan verified between the parties. Delivery time: 10 months; 24 months till run upPayment: before loading, according the following installment plan:30% Down payment after signing the sales contract within 10 days30% FOB Shanghai first ship30% FOB Shanghai second ship10% after 1 year production (time of warranty)Warranty: 1 year full warrantyReservation of title: until receiving the entire payment. Extended reservation of title is valid.100,000 Tons/Year Small Concrete Processing PlantDescription of 100,000 Tons/Year Small Cement Production Equipment:This 100,000 tons/year small concrete processing plant is a kind of small and medium size calcining machine of cement clinker, and it is designed with deflected fire control system. In general, it has the advantages of strong ventilation capacity and quick calcining and cooling down. And technical services are also available. Parameters of 100,000 Tons/Year Small Concrete Processing Plant:No.Name and specificationTechnical parametersAmountRemarks1Apron feederB1000×12.1mQ: 18-110T/h N:15kW1Jiangsu Pengfei Group Co., Ltd2PE600×900 crusherQ: 56T/h N: 55KW1 3HD8964L-A bag filterQ: 4200-5200m3/hN: 7.5KW+0.37KW1Jiangsu Pengfei Group Co., Ltd4FF300S flap valveQ: 6-12T/h1 5TD75 rubber belt conveyorB650×23.022m Q: 140T/h N:5.5kW1 6PC1010 hammer crusherQ: 60-80T/h N=132kW1 7MW-66-12B sleeve environmental protection equipmentQ: 10800-14400m3/h1 8FanC4-73-11-No5.5C Q=14700m3/h , N=22kW1 9TH400 bucket elevatorQ: 58 m3/h N:15kW1 10BZ-1 bar valve600×6002 11TDG65 speed regulation scalesQ: 24T/h2 12Gate400×4004 13TDG50 speed regulation scalesQ: 6.5T/h2 14TDG50 speed regulation scalesQ: 1.5T/h2 15HD8948C bag filterQ: 2000-3000m3/hN: (5.5+0.25)KW3 16TD75 rubber belt conveyorB500; L: 38.85mN:80T/h; N:5.5kW1 17TD75ruber belt conveyorB500×17.1m; α:17°;Q:15T/h; N:3KW1 18400×600 clay crusherQ=10-15T/h; N:15kW;dv≤400mm; dr≤25mm1 19TD75 rubber belt conveyorB500×30.5m; Q:80T/hα:15°42'; N:5.5kW1 20TD75 rubber belt conveyorB500×6.1m;Q:15-20T/hα:10°23'1 21TH315 bucket elevatorC=9.763 Q:35m3/h; N:7.5kW1Jiangsu Pengfei Group Co., Ltd22SM500 coal crusherQ: 5-8T/h; N:7.5kW1 23TH315 bucket elevatorC=13.347m Q:35m3/h; N:7.5kW1 24Gate200×2001 25GZIF electrical vibration machineN: 60W1 269-19No6.3A fanQ:3972m3/h; P:9650Pa; N:18.5kW1 27butterfly valve 1 28GJH2212 dryerφ2.2×12m; Q:10-60T/h; N:22kW1 29DFF300S electric valveQ:6-12T/h; N:0.55kW1 30TH315 bucket elevatorC:26.659; Q:35m3/h; N:11kW1 31CLK4×60 diffusion environmental protection equipmentQ=27000m3/h1 32DFF220 electric flap valveN:0.37kW1 33CWB-15 horizontal electric environmental protection equipmentQ=30000-37400m3/h; loc>99.5%1 34G4-73-11No.9D fanQ=24000m3/h; P: 2670Pa; N:30kW1 35LS200 screw conveyorL: 11m; N:2.2kW1Jiangsu Pengfei Group Co., Ltd36MB2270 ball millφ2.2×7m; Q:20-25T/h; N:380KW1 37DFF400S electric flap valveQ:20-60T/h; N:0.75kW1 38TH400 bucket elevatorC=21.152; Q:58 m3/h; N:15kW1 39QLL4.0m powder separatorN:45kW; φ4m1Jiangsu Pengfei Group Co., Ltd40DFF400S electric flap valve 2 41LS400L=15.500m; Q:36.2m3/h; N:11kW1 42TH315 bucket elevatorC=15.395; Q= 35m3/h; N:11kW1 43WL300 single-pipe machineφ300×1460m; Q:35T/h; N:3kW1 44LS400 screw conveyorL=13.500m; Q:45m3/h; N:7.5kW1 45TH315 bucket elevatorC=21.539; Q= 35m3/h; N:11kW1 46CLK2×7diffusion cyclone environmental protection equipmentQ:12900-18400m3/h1 47CWB.7 horizontal electric environmental protection equipmentQ:15000-18700m3/h1 48DFF150 electric flap valve0.37-0.55Kw1 494-72-11No.6C fanQ:15800m3/h; P:2480Pa; N:18.5kW1 50LS400 screw conveyorL=23.500m; Q:36.2m3/h; N:11kW1 51LS400 screw conveyorL=24.500m; Q:36.2m3/h; N:11kW1 52LS400 screw conveyorL=24.500m; Q:36.2m3/h; N:11kW1 53LS40 screw conveyorL=22.500m; Q:36.2m3/h; N:11kW1 54HD8948C bag filterQ:2000-3000m3/h; N:5.5kW+0.75kW2Jiangsu Pengfei Group Co., Ltd55TH315 bucket elevatorC=23.587m; Q:35m3/h; 11KW1 56Gate300×3001 57LS400 screw conveyorL=8.500m; Q:36.2m3/h; N:5.5kW1 58rigid impeller machine300×300; 1.5kW1 59TH315 bucket elevatorC=15.395m; Q:35m3/h; 11KW1 60TH315 bucket elevatorC=22.051; Q:35m3/h; 11KW1 61SWL250×2000 double-pipe machineQ:11-34m3/h; N:7.5kW1 62LXC-H spiral electronic scales 1 632J5.5×3000 double-shaft machineQ:25T/h; N:15kW1 64QPY36 granulatorφ3.6m; Q:18-22T/h; N:18.5KW1Jiangsu Pengfei Group Co., Ltd65TD75 belt conveyorB500×6.5m; Q:120T/h; N:5.5kW1 66CD0.5-6A electric hoist 1 67φ3×11m mechanical shaft kilnQ:11-13T/h1 68L94WD fanQ:359m3/h; P:294KPa; N:245kW1 69ZLX-9 sound eliminator 1 70LS200 screw conveyorL=4m; 2.2kW1 71LS200 screw conveyorL=8m; 2.2kW1 72LS200 screw conveyorL=11m; 2.2kW1 73PEX150×750 crusherQ:8.35T/h; N:15kW1 74B360 horizontal sealerL=5.5m; Q:21T/h; N:5.5kW1 75TH315 bucket elevatorC:22.563m; 11kW1 76HD8948C bag filterQ: 2000-3000m3/h; 5.5kW-2P1 77CWB-3 horizontal electric environmental protection equipmentQ:4500-7200m3/h1Jiangsu Pengfei Group Co., Ltd78DFF150 electric flap valve0.37-0.55kW1 79C648No.5C fanQ:7200m3/h; P:1850Pa; N:7.5kW1 80LS200 screw conveyorL=6.5m1 81Gate400×4004 82GZ-3 electric vibrating machineQ:25T/h4 83TD-75 rubber belt conveyorB500×30m; 11kW1 84PE250×400 crusher250×400; Q:4-14m3/h; N:15kW1Jiangsu Pengfei Group Co., Ltd85TH315 bucket elevatorC:19.491m;Q:35m3/h; 11kW1 86TH315 bucket elevatorC:17.433m;Q:35m3/h; 11kW1 87Gate300×3003 88Belt scales TDG650Q:24T/h1 89Belt scales TDG500Q:6.5T/h1 90Belt scales TDG500Q:1.5T/h1 91MB2275 grinderφ2.2×7.5m; Q=16T/h;1 92DEF400S electric flap valveQ:20-60T/h; N:0.75kW1 93CLK2×6 diffusion cyclone environmental protection equipmentQ:12120-13500m3/h1Jiangsu Pengfei Group Co., Ltd94DFF150 electric flap valve 1 95CWB6 horizontal electric environmental protection equipmentQ:14200-17000 m3/h; loc>99.5%1 96LS400 screw conveyorL:13.500m; Q:36.2 m3/h; N:5.5kW1 97Y5-48-No.6.3C fanQ:12030 m3/h; P:2592Pa; N:15kw1 98TH315 bucket elevatorC:21.027m; 11kW1 99QLL4.0 powder separatorN:30kW; 3.5m1 100DFF400S electric flap valve0.75kW1 101LS400 screw conveyorL:13.500m; Q:36.2m3/h N:5.5kW1 102TH315 bucket elevatorC:15.395m; Q:35 m3/h; 11kW1 103TH315 bucket elevatorC:21.539m; Q:35 m3/h; 11kW1 104LS400 screw conveyorL:23.000m; Q:36.2m3/h N:11kW1 105LS400 screw conveyorL:25.000m; Q:36.2m3/h N:11kW1 106LS400 screw conveyorL:24.000m; Q:36.2m3/h N:11kW1 107HD8948C bag filterQ:2000-3000m3/h; N:5.5kW+0.75kW1 108Gate300×3006 109Rigid impeller feeder300×3006 110LS400 screw conveyorL:21.500m; Q:36.2m3/h N:11kW1 111TH315 bucket elevatorC:14.371m; N= 11kW1 112D870 rotary screenN:2.2kW; Q:30T/h1 113G4201 packaging machineQ:30T/h; N:11kW1 114MW-N-140-SP bag filterQ:8400-16800; N:3kW+2.2kW+1.5kW1Jiangsu Pengfei Group Co., Ltd115butterfly valveφ2003 1164-72-11No.5A fanQ:11830m3/h; P:2844Pa; N:15kW1 117LS-200screw conveyorL=5m; N:2.2kW2 118LS400screw conveyorL=4.5m; Q:36.2 m3/h; N:5.5kW1 119rubber belt conveyorB800×4000; N:3kW1 Total number Laboratory Physical examination part 1Press machine30 type1Jiangsu Pengfei Group Co., Ltd2Anti-fracture machine50 type1 3cement mortar mixer411A1 4Cement mortar vibration platform85 type1 5Electric jump table 1 6Cement paste blender 1 7Boiling tank 1 8Consistency meter 2 9Blain specific surface meter 1 10Psychrometer 2 11Temperature controller 1 12Geotherm wire 1 13Anti-pressure fixture 1 14Anti-bending fixture 1 15Cement paste pot 1 16Test needle 2 17Paste cup 1 18Feeding hopper 2 19Nickel crucible holder 1 20Spray head(aluminum alloy) 2 21Disc grinderφ1751 22standard sand 1 23K-Bcmp Chemical analysis part 24Chamber type electric resistance furnace8X-4-101 25Constant temperature oven101-21 26Electro-optic analytical balanceTG328A2 27Electro-optic analytical balanceTG328B1 28Water distiller10t/h2 29Magnetic force heating mixer90-22 30Platinum crucible30ml2 31Oxygen recorder 1 32Infrared ray dryer40×452 33Roberval's balance200g2 34Burdening computerPL-11 35Porcelain crucibleφ15 φ20 φ2560 36Ark28×5030 37Volatilization crucible30ml20 38Burette standMarble10 39Thermometer≤100oC10 40Watch glassφ10010 41 φ6010 42Dryerφ2405 43 φ2005 44Electric furnace800W3 45Plastic wares 46Bi-join ball 1 47Ion exchange columnφ50×6004 48Water feeder(cement paste)100-170ml4 49Water feeder(mortar)238ml2 50Ox horn scoop 10 51Plastic scoop 5 52Porcelain plates12×16″4 53crucible tongStainless steel 20″2 54Latex tubing5×720 55Scale bulb6.3W50 56Stainless steel tweezers16cm10 57Water bathTwo holes1 58Water sieveφ125 0.0810 59Water pressure gauge0.16MPa2 60Tee joint 4 61Dry screenφ300 0.92 1500 Tons/Day Cement Processing LineDescription of 1500 Tons/Day Cement Processing Line:Our 1500t/d cement processing line is a new type of dry process cement clinker production line. The φ3.5×54m rotary kiln has been used as rotary kiln, whose end is fitted with five-stage cyclone preheater and decomposition furnace.Its process flow mainly consists of limestone crushing, raw meal grinding, raw meal homogenizing and storing, calcining, and cement grinding. Detailed information about it will be given in the following.1. Limestone crushing:Limestone is crushed by the single-stage hammer crusher, which is usually used to crush medium-hardness brittle ores, like limestone, marl, shale, gypsum, coal, etc. It is capable of crushing large raw ores to the required feeding size, and its discharging grate can easily dispose the moisture and earth in ores. Special protection system is employed in iron feeding, which can send the uncrushed metals to the feeding device. In this way, the operator can stop the machine timely to solve the problem when they hear strange metal sound.In this 1500t/d cement processing line, we use the TKPC16.18 single-stage hammer crusher. And its feeding size is 800mm, its production capacity 250t/h, and its annual utilization rate 25.51%.2. Raw meal grinding:For raw meal grinding, we have HRM2800m vertical grinding mill system.3. Raw meal homogenizing and storing:Our φ15×50mMF homogenizing silo has integrated raw meal homogenizing and storing into one body, and its raw meal storage capacity is about 6500t and the storage period about 2.86 days.4. Calcining:Its calcining system is mainly comprised of single-row five-stage CDC predecomposition system, φ3.5×54m rotary kiln and new-type air girder cooling machine. Its productivity of cement clinker is about 1500t/d, and its heat consumption is about 840Kcal/kg (3511.0KJ/kg). The resolution ratio of calcium carbonate of the feeding materials is more than 90%. Additionally, the extra heat the waste gas is applied in drying raw materials and raw coal.The clinker cooling has employed the advanced grate cooler with a grate bed that has an effective area of 61.8m2, and a clinker temperature that is 65oC higher than the ambient temperature.5. Cement grinding:This 1500t/d cement processing line has two φ3.5×13m tube mills and they are equipped with N-1500 type O-SEPA high-efficiency air powder separator to make up a circulatory grinding system. Their productivity is about 50t/h.List of Main Equipment:NoItem nameName, specification and performanceProductivity (t/h)Quantity (Set)Annual utilization rate (%)Remarks1Limestone crushingHeavy type apron feederSpecification: B1250×11500mmFeeding size: 800mmPower: 30kW200~350125.51 Single-stage hammer crusherModel: TKPC16.18Feeding size: 800mmDischarging size: ≤25mmPower: 355kW250125.512Limestone pre-homogenizingStacker-ReclaimerDistance between rails: 24mTotal installed capacity: 142kWStacker:Stacking method: continuousStacking layers: >400Reclaiming method: full-section reclaimingStacking capacity:600t/hReclaiming capacity: 250t/h1 3Raw meal grindingVertical mill:Specification: HRM2800mmFeeding size: ≤40mmFineness of finished product: 0.080mmFeeding moisture: ≤6%discharge moisture: ≤0.5%Motor power: 1250kW130160.90 4Waste gas Treatment of kilnand millConditioning towerSpecification: Φ7.5×26mAir processing capacity: 400000m3/hFeeding air temperature: 340oC discharged air temperature:150-220oC 182.19 High temperature fanFlow: 400000m3/hTotal pressure: 7500PaOperation temperature: 340oC (instant temperature 450oC)Rotary speed: 1450r/minMotor power: 1250kW 182.19 2350DIBB24 High temperature fanAir processing volume:300000m3/h 7500 Pac.BS930 electronic environmental protection equipmentAir processing capacity:400000m3/hInlet dust concentration: ≤80g/Nm2Outlet dust concentraion: ≤50mg 182.19 Exhaust gas fan of kiln end Flow: 420000m3/hTotal pressure: 1500PaOperation temperature: 150oC Motor power: 355kW 182.19 5kiln inletFive-stage cyclone pre-heater and decomposition furnace systemC1: 2-Φ4300mmC2: 1-Φ5600mmC3: 1-Φ5600mmC4: 1-Φ5900mmC5: 1-Φ5900mmdecomposition furnace:Φ6300mm62.50182.19 6kilnRotary kilnSpecification: Φ3.5×54mInclination: 4% Rotary speed: 0.4~3.96r/minMotor power: 220kW (DC speed adjusting)62.50182.19 7kiln outlet clinker coolingAir girder grate cooler Model: LBTF170062.50182.19 8Cement grindingTube millSpecification: Φ3.5×13mFineness of final product: 320m2/kgMain motor power: 2000kW50258.59 Powder separatorModel: O-Sepa1500Air volume: 1500m3/min 258.599Cement packingEight-mouth rotary packerMesuring accuracy: ±0.25kg per bag90234.18

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