BATURAJA PROCESS OF TEST TRAIN

TCDRI
2016.8.8

CONTENT
1

BASIC PROCESS

1
2 BATURAJA PROJECTINTRODUCTION
2
BATURAJA GENERRALLAYOUT

3
3

BATURAJA PROCESS FLOW

4
4

4
5

1.BASIC PROCESS
1.1 What is the cement?
Cement, powdered inorganic cementitious materials. After adding water and
stirring into a paste, can be hardened in the air or better in the water
hardening, and the sand, stone and other materials firmly cemented together .
1.2. Process for cement production
New dry process cement production line refers to the cement produced by
the new process. The production suspension preheater and kiln outside the
decomposition technique as the core, using new raw material, fuel and
energy saving grinding technology and equipment, across the board with
computer distributed control, realize the cement production process
automation and high efficiency, high quality, low consumption,
environmental protection.

1.3 Process flow of cement productions

Quarry mining crushingraw material preblendingraw material
dosingraw millraw meal preblendingpreheaterrotary kiln
clinker coolerclinker storage dosing for cement cement
grinding cement storage cement packingcement shipment
Normal there are three stages in the whole process:
(1) The first stageraw mill
After the raw materials are crushed ,dried, mixed, ground,they are
made suitable quality raw meal according to a some proportion.
(2) The second stage: clinker burned(preheater ,kiln, cooler)
The raw meal is burned in the kiln, we will get clinkers with C3S
as the main component.
(3) The third stage: cement grinding
Gypsum is added into clinker, sometimes adding some mixed
materials,Then they are ground as cement.

1.4 Composition of clinker

C3S total:5060%)
C2S (total:1532%)
C3A (total311%)
C4AF(total:818%

1.5 Some common questions in the commissioning of raw meal mill system.
No.

Inspection item
The capacity of mill
production is small

Possible reasons

Solution

(1) Low feed rate

(1) Increase feed rate

(2) Low pressure of

(2) Increase pressure of

grinding

grinding

(3) Too fine product

(3) Reduce the speed of

(4) Low gas flow of the classifier

system

(4) Increase gas flow of

the system

6/77

No.

Inspection item
Big vibration of mill

Possible reasons

Solution

(1) No equable feed

(1) Equable feed

(2) Feed suddenly

(2) Stable material

become fine

granularity

(3) Material layer on

(3) Adjust feed speed or

the mill table is too

reduce pressure of

thin

grinding

(4) Too much

(4) Reduce suitably the

circulatory material

speed of classifier

flow

(5) Check whether the

(5) Metal enter mill

metal detector and magnet

separator run normally.

7/77

No.

Inspection item

Possible reasons

Solution

The product is too

(1) Low speed of

(1) Increase the speed of

coarse

separator

separator

(2) Too big gas flow of (2) Reduce gas flow of the
the system

system

Moisture of product is Low gas temperature of Increase gas temperature

4

big

mill outlet

of mill outlet

Unsuitable gas flow of The valves opening

Adjust the opening degree

the grinding system

degree of circulatory

of the circulatory fan inlet

fan are unsuitable.

valves

8/77

No.

Inspection item

Possible reasons

Solution

Unsuitable gas

Unsuitable circulatory Adjust the opening of

temperature of mill

gas flux of mill inlet

circulatory gas valves

Unqualified raw meal Unsuitable materials

Adjust materials ratio

outlet

ratio

9/77

1.6 Clinker forming

Physical and chemical changes in raw meal
1drying, preheating100600
2chemical changes 6001200
CaCO3CaO+CO2
3changes beteen solid and liquid 8001250
2CaOSiO2C2S
3CaOAl2O3 C3A
4CaOAl2O3Fe2O3C4AF
4clinker forming130014501300
3CaOSiO2C3S
5clinker cooling13001000100

10/45

1.7 Cement grinding

The main content of cement
1) Clinker: it is the main content of the production cement, it is up to
the charater of the cements quality .
2) Gypsum: it is a small amount (3 to 5%) .it can adjust the setting
time of cement.
3) Corrective materials: adding amount of mixed materials in cement
can not only adjust variety of cement, increase cement production,
reduce production cost, but also improve some character of cement
in a certain extent.

11/45

1.8 Some common questions in the commissioning of cement mill system.

No.

Inspection item

Possible reasons
1)The

feeding

is

Solution
not 1)To feed symmetrically

symmetrical

2)To stabilize the size of

2)The feeding is too fine material entering mill

3)The material thickness 3)To
is too thin

the

feeding

speed or reduce the pressure

The libration of mill is 4)Inner circulation is too

exquisite

adjust

great

of mill

4)To reduce the rotate speed

5)There is metal in mill

properly(But the production

fineness is guaranteed)
5)To

inspect

detector

and

the

metal
magnet

separator if they working

normally
12/45

No.

Inspection item

Possible reasons

Solution

1)The feeding speed is 1)To increase the feeding

low

speed

The output of cement 2)The pressure of mill is 2)To increase the pressure of
mill is too low

low

mill

3)The system gas flux is 3)To adjust the system gas

low
1)The

flux
separation 1)To

efficiency is low

The

production

increase

the rotate

speed of separator

of 2) The system gas flux is 2)To adjust the system gas

cement mill is too thick high

flux

3) The pressure of mill is 3)To increase the pressure of

low

mill

No.

Inspection item

Possible reasons

Solution
To

increase

the

gas

temperature out of mill

4

The moisture of cement The gas temperature out To

is too high

of mill is low

14/77

reduce

the

feeding

quantity of cement material

2.SPECIFICATION FOR BATURAJA

2.1 Process Specification
2.1.1 Produce Capacity and Produce Method
One dry production line with the capacity of 5000t/d clinker will
be constructed. The double string five-stage cyclones preheater
and TTF precalciner are adopted, when the feed moisture
higher,maybe use four-stage cyclones preheater.
The kiln runs 310 days a year, and the output of clinker will be
1550,000 t/a. The output of cement will be 2081309 t/a.
2.1.2 Construction Scope
The whole production line from the materials and fuels
transported into the factory to the cement storage, packing and
products transported out.
2.1.3 Type of Product Transportation
The bulk and bagged cement will be transported by truck .

2.2 Design Condition

Raw materials characteristics and transportation
Mode of

Material

Sizemm

Moisture%

Limestone

1200x1200x1200

12

Truck

Clay

500

32

Truck

Silica sand

30

12

Truck

Iron ore

30

12

Truck

Gypsum

30

18

Truck

Pozzolana

30

20

Truck

Truck

35

Truck

Fly ash
Coal

200x200x200

2.3 Thermal energy consumption:

730 kcal/kg clinker(Five-stages)
770 kcal/kg clinker(Four-stages)

16/45

transportation

Remark

2.4 Raw Material Proportion Ratio

Raw material proportion ratio

Limestone

Clay

Silica sand

Iron ore

83.01

15.23

0.48

1.28

2.5 Cement Proportion Ratio

Variety

Clinker(%)

Gypsum (%)

Limestone(%)

Pozzolana(%)

Fly ash(%)

OPC

92.5

3.5

4.0

PCC

69.5

3.5

20

4.0

3.0

17/45

2.6 The proximate analysis results of the coal(dry basis)

Coal

Mar

Mad

Vad

Aad

St, ad

35%

10%

38.68%

7.87%

0.63%

18/45

Qnet, ad
(kJ/kg)

20900

2.7 Raw Material Banlance

Natural
Material Name

Material

Consumptionkg/t

moisture proportion

Dry

Dry

Wet

Material Balance Quantityt

Each hour Each day

Wet
Each year Each hour

Each day

Each year

Limestone

10.5

83.01

1280.02

430.19

266.67

6400.1

1984035

297.96

7151

2216799

Clay

32

15.23

234.85

345.36

48.93

1174.2

364015

71.95

1726.8

535316

Raw

Silica Sand

12

0.48

7.4

8.41

1.54

37

11473

1.75

42.1

13037

material

Iron ore

12

1.28

19.74

22.43

4.11

98.7

30593

4.67

112.1

34765

Raw Meal

Raw Meal

100.00

1542.01

321.25

7710

2390116

Clinker

Clinker

PCC

Gypsum

18

Fuel

61.41

208.33
7.87

5000
188.9

1550000
58570

9.6

230.4

71426

71.94

9.0

215.9

66937

11.25

269.9

83671

Pozzolana

20

4.0

Fly Ash
Limestone

2
10.5

3.0
20

43.17

44.05

6.75

161.9

50202

6.89

165.2

51227

287.77

321.53

44.98
156.32
223.8

1079.6
3751.7
5371.1

334683
1163023
1665047

50.26

1206.3

373947

69.5

Limestone

10.5

43.24

48.32

2.25

54

16734

2.51

60.3

18697

Gypsum

18

3.5

37.84

46.14

1.97

47.2

14642

2.4

57.6

17857

52.01

1248.3

386977

Cement

55.95

1342.8

416262

Gypsum

9.84

236.2

73212

12

288

89283

Limestone

47.23

1133.6

351417

52.77

1266.6

392645

Cement

279.75

6713.9

2081309

30.74

737.8

228706

47.29

1135.0

351855

Clinker

Total

50.36
57.55

Clinker
Cement

OPC

3.5

Coal

92.5

35

147.55

227.0

19/45

2.7 Raw Material Banlance

Natural
Material Name

Material Consumptionkg/t

moisture proportion

Dry
Dry

Total

Fuel

Material Balance Quantityt

Wet

Each
hour

Each day

Wet
Each year Each hour Each day

Each year

Gypsum

9.84

236.2

73212

12

288

89283

Limestone

47.23

1133.6

351417

52.77

1266.6

392645

Cement

279.75

6713.9

2081309

30.74

737.8

228706

47.29

1135.0

351855

Coal

35

147.55

227.0

1). Annual operation days: 310 days

2). Heat consumption: 3053kJ/kg.clinker(five-stages )
3). Net calorific value of lignite: 20900 kJ/kg
4). Loss in producing: raw material 0.5%; cement 0.5%; lignite 1%
5). Material consumption: 1.5343 kg/kg.clinker
6). Proportion of PCC and OPC: 80%:20%

20/77

2.8 Storage Method Storage Amount and Storage Period

Material

Storage method

Size(m)

Limestone

Rectangular pre-blending pile

60 (W)x267.5 (L)

Clay

Rectangular pre-blending pile

31.1 (W)x82 (L)

Storage

Capacity (t) Period (d)

2x25000

2x3.4

2x5000

20

Silica sand

42.7

Iron ore
3

Storage

Rectangular pre-blending pile

3000

33.4

5000

22.0

2x6000

49 (W)x185 (L)

Pozzolana

Gypsum

Coal

Rectangular pre-blending pile

49(W)x167(L)

21/45

Storage

Storage Period

Size(m)

Capacity (t)

(d)

Bin

820.9

700m3

2.7h

Bin

4.512.14

110m3

3.0

Bin

4.512.14

110m3

1.2

Raw Meal

Silo

2063.5

20000

2.6

Clinker

Silo

40x43.5

50000

10

Unburned clinker

Silo

10x23.5

1000

12h

2-814.85

2-430m3

2-3.6h

2-614.95

2-250m3

2-9.7h

No.

Storage method

Material

Limestone
5

Silica

Raw Mill Dosing

sand
Iron ore

Clinker

Pozzolana

Cement

Bin
Bin

2-1.3

Mill Dosing
Gypsum

Bin

2-614.95

2-250m3

Limstone

Bin

2-614.95

2-250m3

Fly ash

Silo

1230

2000m3

10

Cement

Silo

3-20x51

30000

22/45

2-1.9

5.1

2.9Main Equipment, Production Capacity

No.

Departments

Equipment

Daily
Shifts
Qty Running
Hour/Year
(d/w) x (h/d)
Hours (h)

Specification

Capacity:1200
t/h
1

Limestone
crushing

Clay crushing

Double
hammer
crusher

Double
with
crusher

shaft Feed size:

1200x1200x12
00mm

8.3

516

2573

9.7

516

3007

5.3

5x8

1643

Grain size:
75mm(95%)
roller Capacity:250t/h
teeth Feed size:
500mm
Grain size:
75mm
Capacity:300 t/h

Coal
crushing

Double
crusher

Feed size:
roller 200x200x200m
m
Grain size:
50mm90%

23/45

No.

Departments

Specification

Equipment
Side stacker

Capacity: 1500 t/h

Daily
Shifts
Qty Running (d/w) x Hour/Year
Hours (h) (h/d)
1

6.7

5x8

2077

Limetone
4

storage

Bridge type reclaimer

Capacity: 1500 t/h

252

Capacity: 1500 t/h

122
1

Side type reclaimer

Belt
conveyor
traveling stacker
5

with

Capacity:300 t/h

5.8

7x8

1798

Bridge
type
bucket
Capacity:150 t/h
excavator reclaimer

11.5

724

3565

Correctives
and
Additives

Side stacker

Capacity:300 t/h

4.9

58

1519

Side type reclaimer

Capacity:200t/h

1.0

724

310

storage

Side type reclaimer

Capacity:150 t/h

4.8

724

1488

Clay storage

24/45

No.

Departments

Qty

Capacity: 360 t/h

4.4

5x8

1364

Bridge
type
Capacity:150 t/h
reclaimer

6.6

724

2046

14.8

724

4588

Equipment
Side stacker

Daily
Shifts
Running
Hour/Year
(d/w) x (h/d)
Hours (h)

Specification

Coal
storage

Capacity:60t/h
(dry)
Product fineness:
90m Residue
8

Coal grinding

Vertical
mill

roller 15%
200m Residue
1%
Product surface
moisture:1%

25/45

No.

Departments

Specification

Equipment

Qty

Daily
Running
Hours (h)

Shifts
(d/w) x (h/d)

Hour/Year

19.3

724

5983

Capacity:400t/h(dry)
Product fineness: 90m
Residue
9

Raw grinding

Vertical roller 12%

mill
200m Residue
1%
Product moisture: 1%

No.

Departments

Equipment

Specification

Qty

Daily Running
Shifts
Hour/Year
Hours (h)
(d/w) x (h/d)

Double-string
five-stages cyclone:
C1: 4-4700 mm
Preheater

C2: 2-6800 mm

C3: 2-6800 mm
C4: 2-6800 mm

10

Clinker
burning
system

Calciner
Rotary kiln

C5: 2-6800 mm
TTF
Gas residence time:>6.0s
4.872m
Capacity:5000 t/d
Grate cooler
Capacity:5500 t/d

Cooler

Clinker size at outlet:

25mm(90%)

Clinker temperature at outlet:

<65C+ambient

27/45

24

724

7440

No.

Departments

Equipment

Specification

Qty

Daily
Running
Hours (h)

Shifts
(d/w) x
(h/d)

Hour/Year

19.2

724

5952

14.0

716

4340

Capacity:
175t/h (OPC)
11

Cement
grinding

Vertical roller Product fineness:

mill
3400 Blaine for OPC;
45m Residue
8% for OPC

12
13

14

Cement
packing
Bulk cement
truck loading
Big bag
packing

8-spout rotary
Capacity:120 t/h
packer
Cement truck
Capacity:150 t/h
loader
Capacity:
60 big bags/h
(1.0ton/bag).

28/45

3.BATURAJA-GENERAL LAYOUT
3-.dwg
The project sits on the ground about altitude of +50m, it is max.37 in the whole
year and average humidity yearly is 84.75 %,it belongs to wet environment. The
general layout main features:
3.1 Select the correct site: According to data analysis of report, the site is located
foundation endurance in the range of 200 ~ 500KPa, in order to avoid overloading the
workshop (such as kiln, raw mill) is arranged on smaller foundation endurance area,
this general layout has been modified too more, at last we get this general layout
matching best the main workshop and location, it can reduce amount of civil
engineering.
3.2 It is reasonable for plant functional zone : In general, the whole
cement plant is divided into four functional areas, they are raw material
preparationarea, clinker production area, cement production shipping area and staff
living area. We can find that staff living area is in the upwind, raw material
preparation area is in the downwind.in this case staff living area can avoid dust from
raw material.

29/45

4. BATURAJA PROCESS FLOW

4-BATURAJA-PL-ALL.dwg
4.1Limestone Crushing and Transportation
Limestone exploited with lump size of 1200x1200x1200 mm shall be transported
by dump trucks to receiving hopper in crushing station. Limestone, taken from the
quarry by dump trucks, are fed directly into the feed hopper and then entered to the
crusher via apron feeder underneath the hopper. One set of hammer crusher with the
capacity of 1200 t/h is planned to be used for crushing limestone. The discharged
grain size should be less than 75mm(95%)The crushed limestone shall be
transported to the limestone Preblending system via belt conveyor. The limestone
station shall be equipped with one bag filter to ensure dust content in exhausted gases
of 10 mg/Nm3 and crane for the purposes of assembly, repair and maintenance.

30/45

4.2 Limestone Pre-blending and Storage

Pre-blending and storage for limestone shall be longitudinal, closed type with total
combined capacity of 50000 tons(limestone) and 3000 tons(H.G..limestone).
Limestone storage shall be equipped one set of side stacker, with capacity of 1,500t/h
For reclaiming equipment, one set of bridge type reclaimer shall be provided with
capacity of 600t/h for raw mill dosing, another set of side type reclaimer shall be
provided with capacity of 150t/h for cement mill dosing. The reclaimed limestone
shall be transported to raw mill feed bin and cement mill feed bin by belt conveyors
At any dust emission position such as belt transfer station etcshall be equipped with
bag filter to control dust content of waste gas 10mg/Nm3.
Magnetic Separator and metal detector shall be installed sufficiently for the purpose
of detecting foreign materials entering the process.
.

4.3 Clay Crushing and Storage

Clay crushing station shall be located at the plant site. Clay exploited from quarry
with lump size of less than 500mm shall be transported by dump trucks to receiving
hopper.
From receiving hopper, clay shall be transported to a double roller with teeth crusher
of capacity 250 t/h by apron feeder underneath the hopper. Clay with the feed size
less than 500 mm, at outlet of the crusher with grain size of 75mm shall be
discharged into a belt conveyor, then being transported to clay storage. The clay
crushing station shall be crane for the purposes of assembly, repair and maintenance.
Crushed clay will be transported to longitudinal storage with capacity of 10,000 tons
by belt conveyors. Clay storage shall be equipped one set of belt conveyor with
traveling stacker, with capacity of 300t/h . For reclaiming equipment, one set of
bridge type bucket excavator reclaimer shall be provided, with capacity must
according to required chemical composition of raw mill product. The reclaimed caly
shall be transported to the raw mill feeding system by belt conveyors without any
intermediate bin and be designed in such way that even feeding can be achieved.

4.4 Correctives and Additives Storage

A dump hopper for correctives and additives will be provided. It will be designed
to be unloaded from dump trucks.
Pre-blending and storage for correctives(silica sand and iron ore) and additives
(gypsum and pozzolana) shall be longitudinal, closed type with total combined
capacity of 4x3000 tons. Storage shall be equipped one set of side stacker, with
capacity of 300t/h . For reclaiming equipment, one set of side scraper type reclaimer
shall be provided with capacity of 200t/h for correctives(silica sand and iron
ore),another set of side scraper type reclaimer shall be provided with capacity of
150t/h for correctives(gypsum and pozzolana) . The reclaimed correctives(silica sand
and iron ore) and additives (gypsum and pozzolana) shall be transported to raw mill
feed bins and cement mill feed bins by belt conveyors
At any dust emission position such as belt transfer station etcshall be equipped with
bag filter to control dust content of waste gas 10mg/Nm3.
Magnetic Separator shall be installed sufficiently for the purpose of detecting foreign
materials entering the process.

4.5 Coal Crushing and Storage

Coal crushing station shall be located at the plant site. Coal exploited with lump size
of 200x200x200mm shall be transported by dump trucks to receiving hopper.
From receiving hopper, coal shall be transported to a belt conveyor by apron feeder
underneath the hopper. Then coal shall be transported to a roller crusher of
capacity 300 t/h by belt conveyor and one set of wobbler roller screen before crusher
shall be provided.Coal with the feed size 200x200x200mm, at outlet of the crusher
with grain size of 50mm90% shall be discharged into a belt conveyor, then
being
transported to coal storage. The coal crushing station shall be equipped with one bag
filter to ensure dust content in exhausted gases of 10mg/Nm3 and electrical hoist for
the purposes of assembly, repair and maintenance.
Crushed coal will be transported to longitudinal storage with capacity of 2x6,000 tons
by belt conveyor. Coal storage shall be equipped one set of side stacker, with capacity
of 300t/h . For reclaiming equipment, one set of bridge type reclaimer shall be
provided with capacity of 150t/h. The reclaimed coal shall be transported to raw coal
bin by belt conveyor.

4.6 Raw Material Proportioning Station

Three feed bins shall be installed for limestone,silica sand and iron ore.Each material
is discharged from bin via apron feeder and weighfeeder according to a certain
proportion,
and then fed into raw mill via belt conveyor. The clay is fed direct to the belt
conveying system to the raw mill through clay reclaimer and belt conveyor.The clay
feeding shall be monitored by the installed belt weighing system on the clay feed belt.
The capacity of each raw material bin is as below:
- Limestone
: 700m3
- Silica Sand
: 110 m3
- Iron ore
: 110 m3
- Clay
: Direct feeding to mill
Magnetic separators, metal detectors shall be installed at convenient positions for
removal of disgusted metals, for that, only pure and clean raw materials can be fed
into raw mill.
Bag filters shall be arranged at dust emission points to ensure dust content in
exhausted gases of 10mg/Nm3.

4.7 Raw Material Grinding and Exhausted Gas Treatment System

One vertical mill is proposed for drying and grinding of raw materials. With the feed size
75mm(95%), the feed moisture 16% (max.) and the residue of raw meal on 90 micron meshes
less than 12%, the output of the mill is considered to be 400 t/h. After grinded and dried, the raw
material mixture are separated by the separator, the coarse material are sent back raw mill and
ground again, while the finished product is lifted by the flow of the gas and collected by the
cyclone separator. Then raw meal will be transported into silo via air slide ad bucket elevator. The
gas goes out of the cyclone, some enter the mill as circling gas and the other enter the atmosphere
through electrostatic precipitator, fan and chimney.
The main heat source for drying the mixed raw materials shall be the exhaust gas from the
suspension preheater and the clinker cooler . When raw mill is running, the exhaust gas from
preheater and clinker cooler will enter the raw mill to dry the raw materials, the rest will enter the
preheater filter and be dusted.
When raw mill is stop, he preheater and clinker cooler exhaust gas will be less than 180C by
spraying water in air conditioning tower, then enter the preheater filter and be dusted.
When raw mill is running, the dust collected by preheater filter, cyclon to coal mill and air
conditioning tower will mix the raw meal, then all be transported into raw meal silo. When raw
mill is stop, the dust will be transported into dust bin by bucket elevator. One set discharger device
is installed at the bottom of bin,dust will be conveyed to kiln feed.
A sampler shall be installed at the discharging chute of the raw meal air slide, and the samples can
be sent to an x-ray analyzer. Then the proportion of raw materials can be adjusted according to
analyzed results so as to ensure the quality of raw meal.

4.8 Raw Meal Blending Silo and Kiln Feeding System

One silo of 20 x 63.5m is considered for continuous homogenization of raw meal
with its capacity of 20000t storage equivalent to a period of 2.6d kiln operating days.
This project uses the TP-3 type control flow silo. When the raw material goes into
the silo, the silo bottom has been devided into 7 zone, when the raw meal discharge
,the raw meal layer can mix both slide lengthways and vertical cutting, in this case we
can get stable chemical composition of raw meal. Because there is an online
analyzer, raw material chemical composition is checked per minute by laboratory ,
and adjust the ratio of raw material on time . The raw mill capacity is 400t / h, the
raw meal silo diameter is 20m, the raw meals density is 1.25t / m3, we can caculate
that thickness of raw meal in the silo is 17mm every layer . Acordding to 40m high
(the height of the effective storage of silo) there are about 2300 raw meal layers.the
tradition raw meal silo only has more 400 layers,So I think it is enough for raw meal
homogenization.
The raw meal is discharged from the silo into the feeding bin .There are load cells for
the feeding bin. The flow control valve, flow meter are installed at the outlets of the
bin for measuring the raw meal. The measured raw meal is fed into the pre-heater by
the bucket elevator and air slide.
The automatic sampler is installed before the pre-heater bucket elevator.

4.9 Coal Grinding

A vertical mill is proposed for drying and grinding of raw coal. With the feed size
50 mm, the feed moisture 35% (max.) and the residue of raw meal on 90 micron
meshes less than 15%, the output of the mill is considered to be 50 t/h. The ground
material is separated by a high efficient separator, the coarse partical will be back to

the mill, while the fine product is sent to the pulverized coal bins by screw conveyor
after collected by a bag filter in every system.
The pulverized coal is stored in their bins,pulverized coal will be discharged at the
bottom by weigh feeders and then weighed and fed into precalciner burns,kiln burners.
Transport and grinding equipment will be closely covered to minimize dust emission.
Bag filters will be equipped at dust emission points to ensure dust content in exhausted
gases of 10mg/Nm3. Necessary equipment will be required to prevent explosion and

fire in the station.

4.10 Preheater and Kiln

Clinker burning system is mainly composed of a rotary kiln of 4.8 x 72m, with
double-stream five-stages low pressure-drop, high-efficiency cyclone preheater and a
precalciner of TTF type. The capacity of this system is designed to be 5000 tons of
clinker per day. The heat consumption of kiln system shall be <3053 kJ/kg-clinker.

when five-stages(equal to 730 kcal/kg-clinker). when the feed moisture higher, maybe
use four-stages cyclone preheater. The ratio of coal consumption between the
precalciner and kiln is set to be 6:4. The decarbonating rate (precalcination) of kiln
feed is expected to reach 90%.
A system of storing and handling diesel for kiln firing during the startup of kiln also
shall be provided. The kiln burner shall be capable of firing diesel also.

4.11 Clinker Cooler and Clinker Storage

The new-developed latest technology high efficiency grate cooler is considered for clinker
cooling. The products temperature is kept at 65C +ambient temperature.The cooler has a
capacity of 5500 tons of cooling clinker per day. A roller crusher shall be equipped at the end
of the cooler for crushing the clinker. Waste gas from cooler shall be partially drawn to kiln
as secondary air, partially ducted to precalciner as tertiary air, partially ducted to cement mill
as drying resource, and the rest shall be classifier by cyclones ,then ducted to raw material
mill as drying resource or dedusted by bag filter together with exhaust gas from preheater.
One silo of 40 43.5m height is used for storing clinker to a total capacity of 50,000 t.
Besides, there is another small-sized silo of dia.10m x 22.5m height which is built to keep
unburnt clinker with its capacity of 1,000 t. One set of bulk loading device is installed at the
bottom of this silo.
Clinker which is discharged from cooler will be fed into the silos through deep pan
conveyor.
Arc valves and pan conveyors are installed under the silos so as to extract the clinker,
which will be sent to the proportion bins of cement mill.
Bag filters shall be equipped at all dust emission points to ensure dust content in
exhausted gases of 10mg/Nm3.

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4.12 Cement Mill Feeding

Two sets (Four bins per set)are set in the cement proportioning station respectively
for clinker, gypsum, pozzolan and limestone. Each material is discharged from silo via
weigh feeder or apron weigh feeder according to certain proportion, and then fed into
cement mill via belt conveyor.
Clinker bin
: 430m3
Gypsum bin
: 250m3
Limestone bin
: 250m3
Pozzolan bin
: 250m3
Bag filters shall be equipped at dust emission points to ensure dust content in
exhausted gases of 10mg/Nm3.
4.13 Cement Grinding System
Two vertical mills are proposed for drying and grinding of clinker,gypsum,limestone
and pozzolana. With the feed size 75 mm(95%), the fine of cement 3400 cm2/g(Blaine),
the output of the mill reaches 175t/h(OPC). The ground material is separated by a high
efficient separator, the coarse partical will be back to the mill, while the fine product is
sent to the cement silos by air slides and bucket elevators after collected by a bag filter in
every system. The gas goes out of dust collector, some of which enter the mill as circling
gas and the other enter the atmosphere through fan and chimney. When hot gas is
required, cooler or oil-fired hot gas generator is used.
Bag filters shall be equipped at dust emission points to ensure dust content in
exhausted gases of 10 mg/Nm3.
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4.14 Cement Storage

The cement from the cement grinding system will be fed into three 18
51m cement silos with total effective capacity of 30,000 tons. Each cement silo
shall have 6 parts for discharging cement to air slides before being transported
cement to feed bins in the Packing Plant. The discharge rate shall be controlled
by flow-control gates activated by sequential aeration at the bottom of cement
silos.
Each cement silo shall have one set of bulk cement loader ,capacity of each
system will be 120t/h.
Bag filters will be equipped at dust emission points to ensure dust content in
exhausted gases of 10mg/Nm3.

4.15 Cement Packing and Loading

Four cement packers of 8-spout rotary type will be equipped. including
automatic bag placer, broken bag splitters, and bag cleaners. Capacity of each
cement packer will be 120T/h, using bag of 50kg type. Cement bag from
cement packer will be cleaned by pneumatic cleaning device and marked with
lot number before being dispatched. To manage the quantity of cement bag
being dispatched, each dispatching route will be equipped with the bag
automatic counter.
Bag cement dispatching system via road way consists of 8 dispatching routes
which are equipped with mobile loader for truck. Capacity of each dispatching
routes will be 120t/h.
Bag filter will be equipped at any discharged points of bucket elevator,
bib in order to ensure the content of dust in exhausted gas outlet is not higher
than 10 mg/Nm3.

4.16 Compressed Air Distribution

There ia a compressor air station set in the factory. To supply the compressed air
steady, nine sets compressor with the capacity of 23m3/min compressors are set for the
factory.
For this air compressed stations, one compressor which is set for standby.
4.17 Oil Storage and Distribution
One set of diesel oil tank with acapacity of 100m3 shall be installed in the plant.
Diesel oil shall be unloaded from tank trucks to storage tanks in the plant though
flow meter.
One set of receiving pipe line with a proper capacity consisting of tube
connector,strainers,pumps,flowmeter and auxiliaries shall be installed.
One set of oil pumping unit with a proper capacity consisting of
strainers,pumps,flowmeter and auxiliaries shall be installed for supplying diesel oil to
the service tanks in the kiln burning house ,raw mill and cement mill site.
4.18 Laboratory
In the main plant area, a central laboratory will be built where the normal chemical
analysis and physical examinations of raw materials, semi-productions and final
product are carried out. All equipments and apparatus necessary for chemical and
physical testing will be included in this laboratory.

Thank you for your

attention!
Name :

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