The fully automatic cement production line is a production line composed of a series of equipment. It mainly consists of processes such as crushing and pre homogenization, raw material preparation homogenization, preheating decomposition, cement clinker burning, cement grinding and packaging.

Processing technology method for cement production line

The production process of Portland cement is representative in cement production equipment. It mainly uses limestone and clay as raw materials, which are crushed, proportioned, and ground into raw materials. Then, they are fed into cement kilns to calcine mature materials, and the clinker is finely ground with an appropriate amount of gypsum (sometimes mixed with other materials or additives).

Cement production equipment can be divided into two types depending on the raw material preparation method: dry cement production lines (including semi dry methods) and wet cement production lines (including semi wet methods).

① Dry process cement production process flow. The method of simultaneously drying and grinding raw materials, or first drying and grinding them into raw material powder, and then feeding them into a dry kiln for calcination into clinker. But there is also a method of adding an appropriate amount of water to the raw material powder to make raw material balls, which are then sent to the Libol kiln for calcination into clinker, called semi dry method, which is still one of the dry production methods.
② Wet cement production process flow. The method of grinding raw materials into slurry by adding water powder and feeding them into a wet kiln to calcine mature materials. There is also a method of dehydrating raw material slurry prepared by wet method, making raw material blocks and calcining mature materials in the kiln, called semi wet method, which is still one of the wet production methods.
The main advantage of dry production is low heat consumption (for example, the heat consumption of clinker in dry kilns with preheaters is 3140-3768 coke/kg), but the disadvantage is that the raw material composition is not easily uniform, the workshop has high dust emissions, and the power consumption is high. Wet production has the advantages of simple operation, easy control of raw material composition, good product quality, convenient slurry transportation, and less dust in the workshop. The disadvantage is high heat consumption (clinker heat consumption is usually 5234-6490 coke/kg).

Process flow of new dry process cement production line:

1.Crushing and pre homogenization
(1) Crushing: In the process of cement production, most raw materials need to be crushed, such as limestone, clay, iron ore, and coal. Limestone is a raw material used in the production of cement, with a larger particle size and higher hardness after mining. Therefore, the crushing of limestone plays an important role in material crushing in cement plants.
(2) Pre homogenization of raw materials: Pre homogenization technology is the use of scientific stacking and retrieval techniques during the storage and retrieval of raw materials to achieve preliminary homogenization of raw materials, enabling the raw material yard to have both storage and homogenization functions.

2.Raw material preparation
In the process of cement production, for every ton of Portland cement produced, at least 3 tons of materials (including various raw materials, fuels, clinker, mixtures, and gypsum) need to be ground. According to statistics, the power consumption of the dry cement production line grinding operation accounts for more than 60% of the total power consumption of the plant, of which raw material grinding accounts for more than 30%, coal grinding accounts for about 3%, and cement grinding accounts for about 40%. Therefore, reasonable selection of grinding equipment and process flow, optimization of process parameters, correct operation, and control of operating systems are of great significance for ensuring product quality and reducing energy consumption.

3.Raw material homogenization
In the production process of new dry process cement, stabilizing the composition of raw materials entering the pit is a prerequisite for stabilizing the thermal system of clinker burning, and the raw material homogenization system plays a critical role in stabilizing the composition of raw materials entering the pit.

4.Preheating decomposition
Preheating and partial decomposition of raw materials are completed by preheaters, replacing some of the functions of rotary kilns, to shorten the length of the kiln. At the same time, the gas material heat exchange process in the kiln is carried out in a stacked state and moved to a suspended state inside the preheater, allowing the raw materials to fully mix with the hot gases discharged from the kiln, increasing the gas material contact area, fast heat transfer speed, high heat exchange efficiency, and achieving the goal of improving the production efficiency of the kiln system and reducing the heat consumption of clinker burning.

(1) Material dispersion
80% of the heat exchange occurs within the inlet pipeline. The raw material fed into the preheater pipeline is deflected upward by the high-speed rising airflow and dispersed.

(2) Gas-solid separation
When the airflow carries the powder into the cyclone, it is forced to rotate and flow in the annular space between the cyclone body and the inner cylinder (exhaust pipe), and moves downwards while rotating, from the cylinder to the cone, extending all the way to the end of the cone, and then turning upwards to be discharged through the exhaust pipe.

(3) Pre decomposition
The emergence of pre decomposition technology is a technological leap in cement calcination process. It involves adding a decomposition furnace between the preheater and the rotary kiln, utilizing the kiln tail rising flue, and installing a fuel injection device to enable the exothermic process of fuel combustion and the endothermic process of carbonate decomposition of raw materials to rapidly occur in a suspended or fluidized state inside the decomposition furnace, thereby increasing the decomposition rate of raw materials into the kiln to over 90%. Move the carbonate decomposition task that was originally carried out in the rotary kiln to the decomposition furnace; Most of the fuel is added from the decomposition furnace, with a small amount added from the kiln head, which reduces the heat load on the calcination zone inside the kiln, prolongs the life of the lining material, and is conducive to large-scale production; Due to the uniform mixing of fuel and raw materials, the combustion heat of the fuel is promptly transferred to the material, optimizing the combustion, heat exchange, and carbonate decomposition processes. Therefore, it has a series of excellent performance and characteristics such as high quality, high efficiency, and low consumption.

5.Burning of cement clinker
After the raw material is preheated and pre decomposed in the cyclone preheater, the next process is to enter the rotary kiln for clinker burning.
In the rotary kiln, carbonate further decomposes rapidly and undergoes a series of solid-phase reactions, producing minerals such as minerals in cement clinker. As the temperature of the material increases, minerals will transform into a liquid phase, and those dissolved in the liquid phase will react to produce a large amount of clinker. After the clinker is burned, the temperature begins to decrease. The high-temperature clinker discharged from the rotary kiln is cooled by a cement clinker cooler to a temperature that downstream transportation, storage, and cement mills can withstand. At the same time, the sensible heat of the high-temperature clinker is recovered to improve the thermal efficiency and clinker quality of the system.

6.Cement grinding
Cement grinding is a process in cement manufacturing that consumes a lot of electricity. Its main function is to grind cement clinker (as well as gelling agents, performance adjusting materials, etc.) to the appropriate particle size (expressed in fineness, specific surface area, etc.), form a certain particle size distribution, increase its hydration area, accelerate the hydration rate, and meet the requirements of cement slurry setting and hardening.

7.Cement packaging
Cement can be shipped in two ways: bagged and bulk.

Outstanding advantages of cement production line

1. Large output, excellent quality, smoother overall operation, and relatively low failure rate, reducing maintenance costs by more than 150000 yuan per year;
2. Environmentally friendly design is more scientific and fully solves the pollution problem of traditional production lines, creating an ideal and green production site;
3. The quality of cement clinker produced is excellent, with an industrial application value increased by 1.5 times, which can attract more users’ attention and have a higher market price;
4. Excellent energy-saving capability and low coal consumption, which can save enterprises at least 200000 yuan in costs annually;
5. Automated operating systems require minimal on-site personnel, are safe and efficient, and reduce labor costs by approximately 80%;
6. The overall land area of the production line has been reduced by 1/4, which has reduced site restrictions and saved the enterprise 300000 yuan in infrastructure costs.

We can provide feasibility study, design, general contracting, production commissioning and other services for cement production lines with a daily output of 500-10000 tons of various specifications.

1. Daily production of 10000 tons
2. Daily production of 5000 tons
3. Daily production of 4000 tons
4. Daily production of 2500 tons
5. Daily production of 500 tons
6. Customizable according to needs