How to Lower Cement Plant Costs

a cement plant project under construction

As your cement plant expert constructor, AGICO always adheres to “the customers’ interests first”. We always consider how to save the construction cost of the cement plant and improve its economic benefits from the perspective of customers.

The profits of a cement plant are determined by many elements, including natural environments, production conditions, product price, fuel price, and raw material price, etc. When building a new dry process cement plant, we will take the following five strategies to reduce your investment and increase your future profits as much as possible.

1. Suit our measures to local conditions

There may be differences among various cement plant projects in many aspects, including geographical location, meteorological conditions, raw and fuel performance, power supply, transportation conditions, product varieties, and market changes. In the project design, we will carry on the targeted design to these aspects, in order to lower the cement plant costs and obtain the best investment benefit.

The cement plant constructed by AGICO.
A cement plant built by AGICO

2. Simplify process flow and reduce project scale reasonably

Engineering design is the key link to control the investment of a cement plant project. To reduce the investment from the design is not simply to reduce the engineering subprojects or lower the technical standards, but to simplify the process flow through technical innovation and design optimization on the premise of ensuring the safe realization of the production objectives, and finally achieve the purpose of reducing the investment cost.

In order to simplify the process flow, we optimize the general layout of the cement plant according to the specific conditions of the project, so as to make the construction process as simple as possible and reduce the number of equipment and pipelines used in the plant. An optimized plan should be able to make the floor area of the cement plant as small as possible, one-time investment as little as possible, and production and operation cost as low as possible.

The cement plant milling system using vertical roller mill
The grinding system designed with a vertical roller mill

For example, in the design of a raw meal grinding system, we will use the combined separator to combine the waste gas treatment system and the material separation system into one. In this way, the process flow is simplified, the internal layout of the workshop is optimized, and the civil engineering space is saved.

3. Appropriate open-air design & integrated design of conveying equipment structure

The open-air structural design can save a lot of civil engineering investment. Therefore, under the premise of environmental conditions, we will try our best to carry out the open-air layout for devices that can be arranged in the open air. In the process of implementing the outdoor layout, we will fully consider the rainproof measures of equipment and buildings, adopt the equipment with a rainproof structure, and cover the exposed motor and electrical devices with rainproof sheds.

In the design of the conveying system, we often integrate the frame and corridor of the belt conveyor and clinker chain bucket conveyor. The corridor of the conveyor is not only the maintenance structure of civil engineering but also the support frame of equipment. The belt and chain bucket pass through the corridor. Compared with the traditional conveying system building form, this design covers a smaller area, has a faster construction speed, and can also arrange cables and process pipelines in the corridor, which further saves the project cost.

The belt conveyor corridor in a cement plant.
Integrated conveyor corridor

4. Reasonable and economical selection of equipment

Equipment selection is directly related to the income of a cement plant. With the continuous development of production technology, we have been able to produce many low energy consumption models. Low energy consumption usually means high profit, but this is not absolute. Although some models of cement equipment have low energy consumption, their price is also relatively high, so it will increase the investment cost. At this time, we will fully listen to the opinions of clients and provide them with a variety of plans for analysis and comparison, and help them select the scheme with the highest economic benefits.

5. The advanced electrical automation system

We use “reliability” and “advanced nature” as the criteria for designing the cement plant electrical automation system.

At present, the commissioning of a cement plant is mainly to adjust the electrical automation equipment and corresponding parameters. There are many factors that affect the operation rate in the electrical automation system. Therefore, the design idea of electrical automation is first of all “reliable”. Especially in large cement plants, the main engine can not be started and stopped too frequently.

The design index of automation represents the technical level of a cement plant. Only with the improvement of automation level, can we reduce the operation workers, reduce the production cost, improve the safety protection measures of the equipment, and improve the stability of production. Therefore, the goal of automation design is always “advanced”.

The central control room of a cement plant.
Electric automation control room

Nowadays, measuring points in large cement plants are becoming more and more, which hugely increases the information to be processed by the control system. Therefore, we apply the field bus technology in cement plant design to enhance the operational efficiency and simplify the control difficulty. The system requires the use of intelligent instruments, the medium and low voltage adopts intelligent MCC (intelligent motor controller), and the bus is connected with the computer system through the network. Although the cost of instruments and transmission will increase, the investment of the computer system, especially communication cable and bridge, will be greatly reduced, and the total investment will be reduced.

AGICO Cement

Over the years, while building cement plants around the globe, AGICO is constantly optimizing and improving the design and construction process of the cement plant to reduce its investment. Our goal is to let customers get the best cement plant project with the least investment.

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