Professional Documents
Culture Documents
TCDRI
2016.8.8
CONTENT
1
BASIC PROCESS
1
2 BATURAJA PROJECTINTRODUCTION
2
BATURAJA GENERRALLAYOUT
3
3
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.
1.5 Some common questions in the commissioning of raw meal mill system.
No.
Inspection item
The capacity of mill
production is small
Possible reasons
Solution
grinding
grinding
6/77
No.
Inspection item
Big vibration of mill
Possible reasons
Solution
become fine
granularity
reduce pressure of
thin
grinding
circulatory material
speed of classifier
flow
7/77
No.
Inspection item
Possible reasons
Solution
coarse
separator
separator
(2) Too big gas flow of (2) Reduce gas flow of the
the system
system
big
mill outlet
of mill outlet
degree of circulatory
valves
8/77
No.
Inspection item
Possible reasons
Solution
Unsuitable gas
temperature of mill
outlet
ratio
9/77
10/45
11/45
Inspection item
Possible reasons
1)The
feeding
is
Solution
not 1)To feed symmetrically
symmetrical
the
feeding
exquisite
adjust
great
of mill
inspect
detector
and
the
metal
magnet
No.
Inspection item
Possible reasons
Solution
speed
The output of cement 2)The pressure of mill is 2)To increase the pressure of
mill is too low
low
mill
flux
separation 1)To
efficiency is low
The
production
increase
the rotate
speed of separator
flux
mill
No.
Inspection item
Possible reasons
Solution
To
increase
the
gas
of mill is low
14/77
reduce
the
feeding
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
16/45
transportation
Remark
Limestone
Clay
Silica sand
Iron ore
83.01
15.23
0.48
1.28
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
Coal
Mar
Mad
Vad
Aad
St, ad
35%
10%
38.68%
7.87%
0.63%
18/45
Qnet, ad
(kJ/kg)
20900
Material
Consumptionkg/t
moisture proportion
Dry
Dry
Wet
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
Material Consumptionkg/t
moisture proportion
Dry
Dry
Total
Fuel
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
20/77
Material
Storage method
Size(m)
Limestone
60 (W)x267.5 (L)
Clay
Storage
2x25000
2x3.4
2x5000
20
Silica sand
42.7
Iron ore
3
Storage
3000
33.4
5000
22.0
2x6000
49 (W)x185 (L)
Pozzolana
Gypsum
Coal
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
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
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
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
Daily
Shifts
Qty Running (d/w) x Hour/Year
Hours (h) (h/d)
1
6.7
5x8
2077
Limetone
4
storage
252
122
1
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
Capacity:200t/h
1.0
724
310
storage
Capacity:150 t/h
4.8
724
1488
Clay storage
24/45
No.
Departments
Qty
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
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
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
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
30/45
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
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.
40/45
45/45