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Application of Cement Production Process and Equipment

  1. Fragmentation and Pre-homogenization

  (1) In the process of crushing cement production, most raw materials are crushed, such as limestone, clay, iron ore and coal. Limestone is the raw material with the largest amount of cement, and its particle size is larger and its hardness is higher after mining. Therefore, limestone crushing plays an important role in material crushing of cement machinery.

  (2) The technology of pre-homogenization of raw materials is to realize the initial homogenization of raw materials by using scientific stacking and reclaiming technology in the process of storage and extraction of raw materials, so that the raw material yard has the function of storage and homogenization at the same time.

  2. Raw meal preparation

  In the cement production process, at least 3 tons of materials (including various raw materials, fuel, clinker, mixture and gypsum) are grinded by every 1 ton Portland cement production equipment. According to statistics, the power consumed in grinding operation of dry cement production line accounts for more than 60% of the power of the whole plant, among 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 operation system are of great significance to ensure product quality and reduce energy consumption.

  3. Raw meal homogenization

  In the production of new dry process cement, stabilizing raw material composition in pit is the precondition of stabilizing clinker firing thermal system. Raw material homogenization system plays the last key role in stabilizing raw material composition in pit.

  4. Preheating decomposition

  Cement machinery completes the preheating and partial decomposition of raw meal by preheater instead of rotary kiln, so as to shorten the length of return kiln, at the same time, make the process of gas heat transfer in kiln in the state of accumulation and move to the internal suspension state of preheater, so that raw meal can be fully mixed with the hot gas discharged from kiln, increase the contact area of raw meal, heat transfer speed and heat exchange efficiency. High rate, to improve the production efficiency of the kiln system, reduce clinker burning heat consumption.

  (1) Material dispersion

  80% of heat transfer is carried out in the inlet pipe. The raw material fed into the preheater pipeline moves upward with the airflow and is dispersed at the same time under the impact of high-speed updraft.

  (2) Gas-solid separation

  When the air carries the powder into the cyclone, it is forced to rotate in the annular space between the cyclone cylinder and the inner cylinder (exhaust pipe), and move downward while rotating. From the cylinder to the cone, it can extend to the end of the cone, then rotate upward, and discharge from the exhaust pipe.

  (3) Predecomposition

  The appearance of pre-decomposition technology is a technological leap in the calcination process of cement equipment. It adds decomposition furnace between preheater and rotary kiln, uses kiln tail riser flue, and installs fuel injection device to make the exothermic process of fuel combustion and the heat absorption process of carbonate decomposition of raw materials rapidly proceed in suspension or fluidization state in the decomposition furnace, so that the decomposition rate of raw materials into the kiln can be increased to more than 90%. The original carbonate decomposition task in the rotary kiln was moved to the decomposition furnace; most of the fuel was added from the decomposition furnace and a few from the kiln head, which reduced the heat load of the calcination zone in the kiln, prolonged the life of the lining, and was conducive to large-scale production; due to the uniform mixing of fuel and raw material, the heat of fuel combustion was transferred to the material in time, so as to make combustion, heat transfer and carbonate content. The solution process is optimized. Therefore, it has a series of excellent performances and characteristics, such as high quality, high efficiency and low consumption.

  5. After the cement clinker is preheated and decomposed in the cyclone preheater, the next step is to enter the rotary kiln for clinker firing. Carbonate decomposes rapidly in rotary kiln and undergoes a series of solid state reactions to produce isominerals in cement clinker. With the increase of material temperature, the minerals will turn into liquid phase, dissolve in liquid phase and react to produce a large amount of clinker. After the clinker is burned, the temperature begins to decrease. Finally, the high temperature clinker discharged from the rotary kiln is cooled by the cement clinker cooler to the downstream temperature that can be withstood by the transportation, storage and cement machinery. Meanwhile, sensible heat of the high temperature clinker is recovered to improve the thermal efficiency and clinker quality of the system.

  6. Cement grinding machinery is the last process of cement manufacturing, and also the most power-consuming process. Its main function is to grind cement clinker (and cementitious agent, performance adjusting material, etc.) to appropriate particle size (in terms of fineness, specific surface area, etc.), form a certain particle size distribution, increase its hydration area, accelerate hydration speed, and meet the requirements of cement paste setting and hardening.

  7. Cement Packaging

  There are two delivery modes of cement out of the factory: bagged and bulk.

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