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1.System Overview
This solution is a dry process cement production line with a designed clinker capacity of ≥3000 t/d. It adopts the core technology of five-stage cyclone preheater + decomposition furnace + rotary kiln + grate cooler, and integrates intelligent control and environmental protection technology. The production line covers the entire process of limestone crushing, raw material preparation, clinker calcination, and cement grinding, and is adapted to the requirements of low heat consumption (≤740 kcal/kg clinker) and low emission (dust ≤30 mg/Nm³), meets environmental protection standards, and supports EPC general contracting services.
2. Core Process System
| Process section | Core equipment | Key technical parameters |
|---|---|---|
| Raw material crushing | Hammer crusher | Processing capacity 550t/h, discharge ≤65mm (90% pass rate) |
| Raw material pre-homogenization | Side cantilever stacker + bridge scraper reclaimer | Limestone yard capacity 24,000t, homogenization coefficient ≥ 8 |
| Raw material grinding | Vertical mill | capacity 210t/h, product fineness ≤14% (0.09mm screen balance) |
| Clinker calcination | Φ4.0×60m rotary kiln + preheater system | Heat consumption 740kcal/kg, C5 outlet material decomposition rate ≥95% |
| Clinker cooling | Third-generation grate cooler | Cooling efficiency ≥ 72%, discharge temperature ≤ 65 ℃ + ambient temperature |
| Cement grinding | Φ3.8 × 13m double-bin ball mill + powder classifier | Single capacity of 70-75t/h, specific surface area ≥ 3400cm²/g |
| Environmental governance | Pulse bag type dust removal system | Dust emission ≤ 30mg/Nm³, filter bag life ≥ 3 years |
3.Process Highlights
Raw material pretreatment
Intelligent crushing: hammer crusher equipped with hydraulic speed regulating feeding system, overload protection response time ≤ 0.5 seconds
Pre-homogenization technology: limestone homogenization coefficient ≥ 8, raw material composition fluctuation ≤ ± 0.5%
Raw material preparation
Vertical mill energy-saving technology:
External circulation ratio ≥50%, reducing power consumption by 15%
Hot blast furnace waste gas utilization rate ≥80% (310℃ preheater waste gas)
Clinker calcination
Five-stage cyclone preheater:
System pressure loss ≤ 5500Pa, C1 outlet exhaust gas temperature ≤ 310 ° C
Decomposition furnace fuel substitution rate ≥15% (support biomass fuel)
Intelligent control of kiln system:
Kiln speed 0.39-4.10r/min stepless speed regulation
Firing zone temperature infrared monitoring accuracy ±10℃
Cement grinding
High-efficiency powder selecting:
Powder selecting efficiency ≥85%, 3-32μm particles accounted for ≥65
Circulating load rate ≤150%, reduce the phenomenon of over-grinding
Environmental protection and energy saving
Waste heat recovery: The residual air of the grate cooler is used for coal mill drying, and the energy saving rate is ≥20%
Zero wastewater discharge: The equipment cooling water is closed-circuited, and the utilization rate is ≥95%
4.Equipment Configuration List
| Process section | Equipment name | Key parameters |
|---|---|---|
| Limestone crushing | Heavy plate feeder | 45kW (frequency conversion control) |
| Hammer crusher | Power 710kW, Processing capacity 550t/h | |
| Raw meal grinding | Vertical mill | Main motor power 2000kW |
| Clinker calcination | Five-stage cyclone preheater | C1 cyclone Φ4600mm |
| Rotary kiln | Slope 4%, main transmission power 355kW (DC) | |
| Cement grinding | Ball mill | Main motor power 2500kW/set |
| Powder classifier | Processing capacity 300t/h | |
| Environmental protection system | Pulse bag dust collector | Filter wind speed 1.2m/min |
5. Advantages of EPC services
Full process coverage:
Design Optimization: Customized thermal balance and material balance solutions based on 100+ national project experiences
Intelligent factory: DCS control system integrates 5000+ monitoring points and supports remote diagnosis
Core equipment guarantee:
The rotary kiln shell is made of Q345C, and the heat-resistant layer has a long life
The grate plate of the grate cooler is made of high-chromium cast iron, with low wear rate
6. Environmental protection and intelligence
Ultra-low emissions:
Dust: Bag dust outlet concentration ≤10mg/Nm³ (measured value)
NOx: SNCR denitrification system controlled emission ≤320mg/Nm³
