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NovaStar, CK101, Cement Production Line, 3000 to 3500 tpd, 1 Million tpy Capacity (New)

Description

  1. Overview
    1. The project of cement production line can produce 3000 to 3500 ton per day, about 1 million tons per year.
  2. Crushing And Conveying Of Limestone
    1. The crushing of limestone is located in factory, incorporating single-stage hammer crushing.
    2. The limestone is carried to hopper by auto-dumper, then the limestone is conveyed to crusher by heavy plate feeder.
    3. After crushing, the crushed limestone is conveyed to elevator by rubber belt conveyor, then to the gyratory screen by elevator lifting.
    4. The eligible product is conveyed to limestone reservoir, and substandard goods is returned to the impact crusher.
    5. The eligible limestone will be conveyed to limestone batching plant by dumper.
  3. Shale (Clay) Crushing And Sulphur Ore Conveying
    1. The shale (clay) and sulphur ore is excavated by fork-lift truck, then conveyed to original material shed, which has capacity of 3000 t.
  4. Original Material Batching Plant
    1. There are three batching rooms respectively for limestone and shale (clay) and sulphur ore.
  5. Raw Material Homogenization And Kiln Feeding System
    1. There are two sets of continuous raw material homogenization silo (Φ15 m), with capacity of 10,000 t. After weight-loss measurement for homogenization material, the material will be delivered to preheater inlet by air delivery chute and bucket elevator, dosing valve and lock valve.
  6. Clinker System And Clinker Cooling Conveying System
    1. There are five-phase suspension preheater, pre-calciner, rotary kiln, grate cooler in the clinker department, with clinker producing capacity of 3000 t per day.
    2. After pre-heating in the preheater and decomposition in the pre-calciner, it is calcination in the rotary kiln. The clinker will be cooled in the grate cooler leveling horizontal. The large pieces of clinker will be delivered to clinker storage by bucket chain.
  7. Clinker Storage
    1. Together with the clinker, the dust collected by cooler grate bag filter will be elevated to bucket elevator via chain bucket conveyor. When it arrives the top of the storage, the clinker and dust will be storaged in the clinker silo (2 to Φ15 × 400 mm) by multi-disc clinker conveyor.
    2. Gypsum is reclaimed by forklift truck. After crushing, it will be sent to raw material shed by belt conveyor, with 1000 tons of storage capacity.
  8. Cement Batching
    1. In the batching station, there are four batching warehouses respectively for cement clinker, gypsum, mixed materials. Inside these warehouses, there are weighing feeders used to measure materials to be given. The mixed material will be discharged to cement mill via belt conveyor.
    2. There is a magnetic separator provided in the conveyor belt before discharging to cement mill.
    3. It is used to remove iron pieces. In the belt conveyor head, there is metal detector to prevent damage to cement mill.
  9. Cement Grinding
    1. It incorporates cement mill and roller press system for cement grinding. After batching of cement clinker, gypsum, mixed materials, they are pressed by roller press and broken by beater, then conveyed to cement mill. The qualified cement will be elevated to the cement silo storage by bucket elevator.
  10. Cement Storage And Bulking
    1. 4 to Φ15 × 350 mm round silos are used for cement storage, the total reserves of 30,000 tons. After cement-unloading from the silo bottom, the cement will be conveyed to the bulk cement packing workshop and automotive library by the chain conveyor.
  11. Cement Packaging And Finished Product Storage
    1. Two sets of eight mouths cement packaging machines are incorporated for cement packaging, with capacity of 120 t per hour per set. The packaged cement will be sent to finished products warehouse.
  12. Central Laboratory And Compressor Station
    1. There should be a central laboratory responsible for the entire plant fuel, semi-finished and finished product testing; and set a compressor station for plant compressed air providing.
  13. Control System
    1. The whole plant is controlled by the most advanced DCS centralized control and automatic control of each section. It can be effectively controlled and operated by the central control of cement clinker production operation of the entire process.
  14. Plant Advantages
    1. Compact layout for whole plant, process smoothly. Function areas designs according to local environment, easily to manage.
    2. Vertical grinding mill is adopted, reducing the grinding power consumption.
    3. Modified central control room and continuous homogenization silo is adopted to make sure quality require for clinker.
    4. New preheater system is incorporated, which can 100% guarantee calcined anthracite. Preheater system can also adapt well to coal quality and raw materials changing.
    5. The kiln and cooler exhaust gas is used as drying heat sources for raw material and coal drying which can significantly save energy.
    6. Except for coal transportation, all bulk powder materials are used in mechanical conveyor to save energy.
    7. All belts and the top gallery incorporates open layout to maximize the use of space to reduce construction costs.
    8. There are filter for clinker kiln and coal mill and other operation equipments. It not only comply with environmental requirements both inside and outside the plant, but also to meet labor protection standards for each post.
    9. To reduce the manual repair, maintenance and other labor-intensive, large-scale overhaul of the necessary equipment design a variety of maintenance equipment, all other devices are set to overhaul the hook, both to facilitate the repair and maintenance, and save the investment.
  15. Main Equipments For Cement Plant
    1. Limestone crushing: single-stage hammer crusher, capacity 650 t per hour, charging size less than 1000 mm, discharging size ≤ 25 mm, 1 set.
    2. Storage and conveying for limestone and raw material: stocker, capacity 800 t per hour, charging size ≤ 25 mm, 1 set.