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1. System Overview
This solution is a new dry process cement production line with a designed clinker capacity of 1000 t/d. It adopts the core technology of five-stage cyclone preheater + decomposition furnace + rotary kiln + grate cooler, and is suitable for raw materials such as limestone, clay, and iron ore.
2. Core technology and equipment configuration
| Process section | Core equipment | Key technical parameters |
|---|---|---|
| Raw material crushing | Single-stage hammer crusher | Processing capacity 100-140t/h, discharge ≤75mm |
| Raw material drying | Dryer | Processing capacity 100-140t/h, discharge ≤75mm |
| Raw material preparation | Closed-circuit raw material ball mill | Production capacity 45-55t/h, specific surface area ≥3200cm²/g |
| Powdered coal preparation | Air-swept steel ball coal mill | Production capacity 5.5-7.6t/h, fineness R80μm≤12% |
| Clinker calcination | Rotary kiln + five-stage preheater system | Heat consumption ≤3400 kJ/kg, decomposition rate ≥90% |
| Clinker cooling | Monocular cooler | Discharge temperature ≤65℃+ambient temperature, heat recovery rate ≥60% |
| Cement grinding | High-yield and high-fine cement ball mill | Production capacity 27-31t/h, specific surface area ≥3600cm²/g |
| Environmental governance | Pulse bag dust collector + denitrification system | Dust ≤20mg/Nm³, NOx ≤320mg/Nm³ |
3. Process highlights
Efficient raw material pretreatment
Single-stage crushing: Hammer crusher can crush limestone to ≤75mm in one step, reducing equipment investment by 15%
Dynamic homogenization: Raw material pre-homogenization yard capacity ≥3 days of consumption, homogenization coefficient ≥8
Intelligent calcination control
Five-stage preheater: C1 outlet exhaust gas temperature ≤320℃, system pressure loss ≤5000Pa
Decomposition furnace fuel substitution: support biomass fuel (substitution rate ≥15%), CO₂ emission reduction 10%
Energy-saving grinding technology
Closed-circuit raw material mill: Powder classifier efficiency ≥85%, circulation load ≤150%
High-fine cement mill: 3-32μm particles account for ≥65%, hydration activity increased by 20%
Environmental protection in-depth treatment
Multi-stage dust removal: cyclone dust removal (efficiency ≥ 80%) + bag dust removal (emission ≤ 20mg/Nm³)
SNCR denitrification: ammonia consumption ≤ 3.5kg/t clinker, NOx emission reduction efficiency ≥ 50%
4. List of core equipment
| Equipment name | Quantity | Key parameters |
|---|---|---|
| Single-stage hammer crusher | 1 | Power 200kW, processing capacity 140t/h |
| Rotary kiln | 1 | Slope 3.5%, speed 0.5 - 3.0r/min |
| Five-stage cyclone preheater | 1 set | System thermal efficiency ≥55% |
| Grate cooler | 1 | Secondary air temperature ≥1000℃ |
| Cement ball mill | 1 | Main motor power 1000kW |
| Packaging machine | 2 | 8-mouth rotary, accuracy ±0.5kg |
