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F.L. Smidth, Allis Chalmers, 1.2 Million Tons/Year Cement Plant

Description

  1. Overview
    1. Inventory number: E-6657
    2. Cement plant inventory list
    3. 1.2 million tons per year cement plant
  2. Raw Milling
    1. Two ball mills, 9 ft. 6. diameter x 18 ft. 8. long, F.L. Smidth, 19.1 rpm, 74.5% critical, 800 hp synchronous 2400V, capacity 52 tons per hour each at 90% -200 mesh, ball load 40-50 tons 31% (1948) - Raw Mills #1 and #2
    2. Each ball mill includes:
      1. 16 ft. diameter Sturtevant separators with 150 hp motor
      2. Elevators - 50 hp, 300 tons per hour
      3. F-K pump, 150 tons per hour, 125 hp
      4. Clean up elevator 5 hp
    3. Two ball mills, 9 ft. 6. diameter x 18 ft. 8. long, F.L. Smidth, 19.1 rpm, 74.5% critical, 800 hp synchronous 2400V, capacity 52 each (1948, 1950) - Raw Mills #3 and #4
    4. Each ball mill includes:
      1. 16 ft. diameter Sturtevant separators with 150 hp motor
      2. Elevators - 50 hp, 300 tons per hour
      3. F-K pump, 225 tons per hour, 100 hp
      4. Clean up elevator 3 hp
    5. One ball mill, 9 ft. 6. diameter x 18 ft. 8. long, F.L. Smidth, 19 rpm, 74.5% critical, 800 hp synchronous 2400V, capacity 52 tons per hour at 90% -200 (1952) - Raw Mill #5
    6. Ball mill includes:
      1. 16 ft. diameter Sturtevant separator with 150 hp motor
      2. Elevator 50 hp, 300 tons per hour
      3. F-K pump
    7. One ball mill, 9 ft. 6. diameter x 18 ft. 8. long, F.L. Smidth, 19 rpm, 74.5% critical, 800 hp synchronous 2400V, capacity 30 tons per hour at 90% -200 - Raw Mill #6
    8. Ball mill includes:
      1. Fan 300 hp synchronous 2400V
      2. 42,000 cfm exc 8.8A DC 250V
      3. Buell classifier
      4. Bucket elevator
      5. Fan
  3. Kiln Area
    1. Five rotary kilns, 10 ft. diameter x 350 ft. long, F.L. Smidth, two 100 hp DC drive motors, 60 to 80 rpm, capacity of 20 tons per hour each, 59.9 therm/ton - Rotary Kilns #1 through #5
    2. Each kiln system includes:
      1. I.D. fan with 400 hp
      2. Clinker cooler, 5 x 21 grate type
      3. 47,000 cfm baghouse dust collector
      4. Bucket elevators
      5. Raymond coal mill, model 573, 250 hp, rated at 13 tons per hour
      6. Alternative fuel oil and natural gas burners
      7. Deltech waste heat recovery boilers, 24,760 pounds of steam per hour at 900°F
    3. Kilns #1, #2, #3 new in 1948; #4, #5 new in 1952
    4. Two rotary kilns, 10 ft. diameter x 12 ft. diameter x 310 ft. long, Allis Chalmers, pre-heater design, 500 hp gyrol drive, 500 hp I.D. fan, capacity of 20 tons per hour - Rotary Kilns #6 and #7
    5. Each kiln system includes:
      1. Clinker cooler, 7 ft. diameter x 41 grate type, 67,000 cfm
      2. Baghouse dust collector, 95,000 cfm
      3. Raymond coal mill, M/N 573, 250 hp, 130 tons per hour
      4. Deltech waste heat boilers
      5. Alternative fuel oil and natural gas burners
      6. Kilns #6 and #7 new in 1959
  4. Finish Milling
    1. One ball mill, 10 ft. diameter x 10 ft. long, Marcy Mill, 17.6 rpm, 72.5% of critical, 800 hp synchronous 2400V, capacity 42 tons per hour - Finish Mill #1
    2. Ball mill includes:
      1. Elevator #1 - 30 hp, 100 rpm
      2. Elevator #4 (clean up), 7.5 hp, 84 rpm
      3. 16 ft. diameter Sturtevant air separator
      4. Bucket elevators
      5. Norblo dust collector
      6. F-K cement pump
    3. One ball mill, 9 ft. 6. diameter x 18 ft. 8. long, F.L. Schmidt, 19.1 rpm, 74.5% of critical, 800 hp synchronous 2400V, capacity 35 tons per hour (1948) - Finish Mill #2
    4. Ball mill includes:
      1. Elevator #1 - 30 hp, 100 rpm
      2. Elevator #5 (clean up), 7.5 hp, 84 rpm
      3. 16 ft. diameter Sturtevant air separator
      4. Bucket elevators
      5. F-K cement pump
      6. Norblo dust collector
    5. One ball mill, 9 ft. 6. diameter x 18 ft. 8. long, F.L. Schmidt, 19.1 rpm, 74.5% of critical, 800 hp synchronous 2400V, capacity 14.7 tons per hour at 3600 Blaine (1952) - Finish Mill #3
    6. Ball mill includes:
      1. Elevator #6 - 25 hp, 92 rpm
      2. 16 ft. diameter Sturtevant air separator
      3. Bucket elevators
      4. F-K cement pump
      5. Norblo dust collector
    7. Four ball mills, 7 ft. diameter x 30 ft. long, Allis Chalmers, 21.2 rpm, 70.5% of critical, 600 hp synchronous 2400V, capacity 17.4 tons per hour at 3600 Blaine (1944) - Finish Mills #4, #5, #6 and #7
    8. Each ball mill includes:
      1. 16 ft. diameter Sturtevant air separator
      2. F-K cement pump
      3. Norblo dust collector
    9. Two ball mills, 12 ft. diameter x 17 ft. long, F.L. Smidth, slide shoe mills, with Symmetro drive, 17.6 rpm, 78% of critical, 1400 hp synchronous 2400V, capacity 27 tons per hour each at 3600 Blaine (1957) - Finish Mills #8 and #9
    10. Each ball mill includes:
      1. Symmetro gearbox with 720/17.6 gear ratio
      2. Elevators #7 and #8, 30 hp
      3. O-Sepa classifier
      4. F-K cement pump
  5. Power House
    1. Seven waste heat boilers, each 23,000 pounds of steam per hour
    2. Two fuel-fired boilers, each 40,000 pounds of steam per hour
    3. Two turbines rated 7500 kW with steam at 600 psig and 850°F, exhausting at 1.5 inches high, back pressure 3600 rpm
    4. Two generators rated 7500 kW, 2400V, 60 Hz, 0.8 p.f., approximately 10 pounds steam per kWh
  6. 1977 Plan
    1. Total kWh: 118,000,000
    2. Pounds steam per kWh: 10.22
    3. Pounds steam per hour waste: 118,000
    4. Pounds steam per hour auxiliary: 7,700
    5. Pounds steam per hour fuel: 28,000
    6. Therms per month: 316,114
  7. Miscellaneous Equipment
    1. One traveling stacker system, rail mounted, two stockpiles 500 ft. long
    2. Seven Raymond coal pulverizers, bowl mill model 573, 200 hp motor, complete system with fan, ductwork, feed hoppers, etc., rated at 13.5 tons per hour
    3. One bag packer, St. Regis, 4-spout, complete system
    4. 96 baghouse dust collectors, to 90,000 cfm capacity
    5. 20 belt conveyors, 24., 36. and 48. widths, to 1,100 ft. length
    6. Four air compressors, Ingersoll Rand XLE type