6 Tips To Make Your Cement Plant More Successful

As we all know, the cement industry is a big part of the building materials industry. In recent years, the cement plant technology developed fast, more and more reconstruction technologies appear.

For every cement plant manufacturer, the right strategies or tips must top the list on the working plan. A good tip can improve the process, capacity, the productivity of your cement plant. There are some ways that should be considered to update a cement manufacturing plant, such as cement plant design, raw materials, fuel, cement equipment and power, and etc.

If you are looking for ways to improve your cement plant, take 5 or 6 minutes to get your answer now.

1. Using hammer crusher at the secondary crushing, greatly reduce the size of limestone

The feeding size of limestone is a vital factor to affect the production capacity of the raw mill. In the cement crushing plant, there are 4 common types of cement crusher to process raw materials into requires sizes, such as jaw crusher, cone crusher, impact crusher, and hammer crusher. These 4 cement crusher has its own advantages to be suitable for various section of cement crushing plant.

• Jaw crusher is applied to the ore, rock, and raw materials with a compressive strength value that is less than 329Mpa. It has advantages of simple structure, stable performance, and low cost.
• Impact crusher has wide applications; apply for the materials that have compressive strength more than 350Mpa.

Hammer crusher is a high-efficient crusher that combines advanced technology home and board. It has advantages of high crushing efficiency, large reduction ratio, little wear, low energy consumption, smooth operation, and convenient maintenance. Hammer crusher is considered as ideal crushing equipment and widely applied to the secondary crushing in the rotary kiln cement plant.

2. Using microcomputer proportion system, promote raw meal qualification rate

The microcomputer proportion system is very common in the raw mill blending, mainly select measuring equipment like bucket scale, speed belt scale, cantilever scale, nuclear scale, etc. the microcomputer proportion system changes the situation of big error and low accuracy that is caused by the manual or mechanical operation. It greatly increases the qualification rate of outlet raw meal, has made an important contribution to stabilizing the calcining system of rotary kiln, and improves the clinker quality of rotary kiln.

3. Homogenization and storage of raw materials

Cement raw materials production is the base, kiln production is key, the stability of raw meal quality is the prerequisite of stability of rotary kiln thermal regulation. As we mentioned above, the Pre-homogenization of fuel and microcomputer proportion system can increase the qualification rate of outlet raw meal, and the raw material homogenization can improve the qualification rate of inlet raw meal. According to the principle of adaptation to local conditions, homogenize outlet raw meal firstly, and then store them, or directly send all raw meal into raw meal storage silo to avoid stopping grinding caused by homogenization silo failure. Two blanking points are set at the bottom of each raw meal storage silo, which can realize simultaneous blanking.

4. Transformation of rotary kiln, improve the clinker quality

The purpose of the comprehensive reconstruction of the cement rotary kiln is to improve the working capacity, improve the central ventilation of the rotary kiln, strengthen the insulation of the rotary kiln, and ensure the stability of the kiln. The transformation of rotary kiln also efficiently improves the clinker both in yield and quality, decrease energy consumption, reduce the labor intensity.

5. High-efficiency and energy-saving drying technology, increase drying efficiency

The technology of high-efficiency and energy-saving rotary kiln dryer adopts a new type of combined material lifting device, which has a novel and unique structure, and it can ensure that the material entering the dryer falls in the shape of a “waterfall” on its cross-section and moves forward in the shape of a “wave” along the axial direction. The whole set of material lifting device has properties of guidance, uniform flow resistance and etc. The comprehensive high-temperature fluidized bed furnace has strong adaptability to coal and can be used with inferior coal, gangue, and slag. The system adopts centralized control and instrument operation to reduce the labor intensity of workers.

6. Using frequency conversion technology, upgrade and transform electrical energy saving

Except for the high-temperature fan is controlled by high-voltage inverter, traditional fans regulate air volume by changing the opening of the damper or the coupling, and there is a large energy loss. According to the operation of the working fan, we can make a solution of the frequency conversion renovation of fans as flows to promote energy efficiency.

It can be seen from Table1 after the frequency conversion control is adopted, the electricity-saving 7.848 million kWh, which is equivalent to 3170.6t standard coal, and the cost reduction effect will be very obvious. At the same time, the air volume and pressure can be regulated stably by frequency conversion control, which is convenient for the control of the cement production process and increases the output. Reduce the vibration and wear of equipment, indirectly reduce the cost of equipment operation and maintenance, environmental noise significantly improved; reduce the bearing temperature of motor and fan, and prolong the service life of motor and fan blade.