Product Name: Cement Plant
Capacity: 5000 – 10000 TPD
Equipment: crusher, conveyor, cyclone preheater, rotary kiln, cement grinding mill, etc.
In contrast to the mini cement plants, we usually call the cement plant with a clinker production capacity of more than 5000 TPD as the large cement plant. As a manufacturer who specializes in cement technology development and equipment upgrading and has over decades of cement machinery manufacturing experience, AGICO has the ability to design and build large cement plants with clinker production of up to 10,000 tons per day.
Large Cement Plant Advantages
For large-scale cement companies, mini cement plants with low output are difficult to support their high sales, so they usually prefer to build large cement plants with greater production capacities.
With the increase of plant scale and production capacity, the size and capacity of the crusher, mill, kiln, and other machines in the cement plant also increase correspondingly. Therefore, the increase of plant scale should be accompanied by the growth and development of cement manufacturing machinery so as to maintain or even improve the efficiency and productivity of cement plants.
Compared with mini cement production lines, large cement plants have higher energy consumption but take into account their output, they actually have higher energy utilization rate and production efficiency, which can save production costs for cement manufacturers in the long run. Also, the operating efficiencies of large plants are high. The fuel consumption is around 650 – 700 kcal/kg clinker; power consumption is between 65-80 kWh/ton, and man hours required per ton of cement are as low as 0.15.
Cement Making Machinery in Large Cement Plant
AGICO large cement plants are best suited for manufacturing cement by dry process. The cement making machines in our large cement plants include cement crushers, cyclone preheating systems, rotary kilns, cement mills, and other auxiliary equipment.
We could install four types of crushers in our large cement plants for the raw material preparation process: hammer crushers, jaw crushers, cone crushers, and impact crushers.
The purpose of raw material preparation in the dry process of cement manufacturing is to reduce large-sized raw materials to the proper size and mix them into homogenized raw meals. We will install the most suitable crushing machinery in the cement plant according to the raw materials and production requirements of customers, so as to achieve economic and green production as much as possible.
The application of cyclone preheating system in cement plant hugely reduces the heat loss and fuel consumption in the clinker burning process, and also significantly reduces the floor area and pollution emission of the whole plant.
The 5-stage cyclone preheater is the most installed preheating system in our large cement plants. According to customers’ requirements, we could design other stage preheaters for the cement plant. The cyclone preheater uses hot exhaust gas from the rotary kiln as its heat source. Before entering the rotary kiln, the cement raw meal heat exchanges with the high-temperature gas in the preheater to preheat.
The rotary kiln is where the burning phase of the cement manufacturing process takes place; it is the core part of a cement plant. The raw meal in the rotary kiln will be heated to 1,500℃ during the burning process to form cement clinker.
The production capacity of a cement plant is directly determined by the capacity of the rotary kiln. Our large rotary kilns can fully meet the requirement of bulk cement production. Together with the advanced preheating system, our rotary kilns could achieve high rotary speed and high output per unit volume. The good sealing effect of our rotary kilns allows them to fully recycle the waste heat and produce high-quality clinker.
Cement mills are used for raw material reduction and cement grinding in the cement manufacturing process. The cement grinding process is the final manufacturing stage at a cement plant. After this process, the clinker will become fine cement powders and ready to be packed.
The most used cement mills in our large cement plants are cement ball mills and vertical roller mills. Both of them can well undertake the task of cement grinding, we will take their production efficiencies, power consumptions, investment costs, product particle shapes and sizes, maintenance fees, and other elements into account and decide which one to use when designing a cement plant.