2500 Tpd Dry Process Cement Plant

2500 Tons/Day Dry Process Cement Plant

Process Flow of 2500Tons/Day Dry Process Cement Plant:
The main process flow of this 2500t/d dry process cement plant is as follows:
1. Crushing, Conveying and Storing of Limestone.
First, limestone is crushed by the MB56/75 crusher. When the maximum feeding size is not more than 1500mm and the discharging size is not more than 75mm, the crushing capacity of this machine is 500 to 600t/h.
Second, the crushed limestone will be transported by belt conveyor to the Φ80m round prehomogenization yard whose storage capacity is 34100t.
Third, the crushed limestone will be prehomogenized and then stored in this yard. Additionally, the stacking capacity of our stacker is 800t/h, and the reclaiming capacity of reclaimer is 500t/h.
Finally, the prehomogenized limestone will be sent to the batching station for raw materials.

2. Storing, Crushing and Conveying of Auxiliary Raw Materials.
The open storage yard for sandstones has a specification of 60 mx20m, and a storage capacity of 5100t. And the open storage yard for iron ores has a specification of 32 mx20m, and a storage capacity of 2730 t.

PC1609 hammer crusher is used to crush both sandstones and iron ores. When the feeding size is not more than 600mm, and discharging size less than 25mm, its crushing capacity is 50 to 70t/h.

The crushed sandstones and iron ores will be sent by the belt conveyor to batching warehouse for storage.

The pulverized coal will be stored in the batching warehouse for storage through the self-discharging system.

3. Batching Station for Raw Materials.
In the batching station, there are four batching warehouses respectively for limestone, sandstones, iron ores, and pulverized coal, and their specifications are φ12 mx25m, and storage capacity are 2200t,1600t, 2200t, and 770t respectively. Inside these warehouses, there are weighing feeders used to measure materials to be given.

4. Grinding of Raw Materials and Waste Gases Treating.
MLS3626 vertical mill is used to grind raw materials, and waste gases from preheater are applied in drying. The whole production capacity is 185t/h.

Grinded raw meal is separated by the fine powder separator, and then mixed with powder in the conditioning tower and electric environmental protection equipment. Finally it will be sent to the homogenizing warehouse for homogenization as well as storage.

Waste gases from the mill will take purification treatment in the electric environmental protection equipment before discharged into the air.

5. Homogenizing of Raw Meal.
Our CP homogenizing silo has a specification of Φ18mx50m, and its effective storage capacity is 9000t.

6. Calcining and Storing of Clinker.
The specification of our RF5/2500 decomposition furnace isΦ4.0x60m, and our round 2-φ18x40m warehouse has an effective storage capacity of 2-10000t. Additionally, the final discharging gas has a dust content less than 100mg/m3 if in standard conditions.

7. Storing and Conveying of Raw Coal and Pulverized Coal.
Raw coal will be stored and prehomogenized in a crane room with a specification of 21mx113m and a storage capacity of 9300t. There are two raw coal silos in the crane room, and weighing feeder can also be found in that room. A MPF1713 coal grinder is used to grind coal. When the moisture of feeding materials is no more than 10%, the moisture of pulverized coal is no more than 1%, and the particle size of raw meal is no more than 50mm, the output of the whole system is 20t/h.

The pulverized coal will be sent to two silos for storage, and the purified waste gas is discharged into the atmosphere. There is also measuring system in these two silos.

8. Drying and Conveying of Slag and Crushing and Conveying of Gypsum.
The drying capacity of ourφ2.4x18.350m dryer is more than 30t/h, and the open storage area has a storage capacity of 4000t. When the feeding size is no more than 600mm and the discharging size is no more than 25mm, the productivity of our PFC-1609 impact hammer crusher is 50 to 70t/h.

9. Grinding, Conveying and Storing of Cement.
In the cement batching station, there are four batching rooms respectively for clinker, gypsum, limestone and slag. And the clinker one has a specification of φ10 mx22m and a storage capacity of 2000t. The specification of batching rooms of gypsum, slag and limestone is φ8 mx22m, and their storage capacity is 800t, 400t and 900t respectively. The packaging capacity of packing machine is 90t/h.
Main equipment list

No.NameSpecification and SizeQ'tyCapacity(t/h)1Limestone & Marl crusherSingle stage,hammer type
Feed size: <1200x900x900mm
Product size: <70mm R95%
Main motor: 600kW14002AlluviumstackerSuspended arm side stacking
15003AlluviumreclaimerBridge scraper12504Limestone and clay stackerSuspended arm side stacking
14005Limestone and clay reclaimerBridge scraper11506Raw millVertical type
Feed size: <75mm
Product fineness: <12%R90
Feed moisture: max.6.5%
Product moisture: <0.5%
Main motor: ~2000kW12007Raw mill fan
Air flow: ~420000m3/h
Pressure: 10500Pa
Air temperature: 100ºC, max.150ºC
Dust inlet: <100g/Nm3
Main motor: ~1800kW18Preheater fan
Air flow: ~460000m3/h
Pressure: 7500Pa
Air temperature: 310ºC, max.450ºC
Dust inlet: <80g/Nm3
Main motor: ~1500kW1
No.NameSpecification and SizeQ'tyCapacity(t/h)9EPfor kiln and raw mill
Air flow: ~480000m3/h
Filter section: ~161m2
Inlet airtemp.: 100~150ºC
Dust inlet: <80g/Nm3
Dust outlet: <70mg/Nm3110Preheater and precalcinerSingle series, 5-stage
C1: 2-Φ4500mm
C2, C3: Φ6460mm
C4, C5: Φ6760mm
Precalciner: Φ5060mm
Pressure loss: <5500Pa
Outlet air temp.: 320ºC1set2500t/d11Rotary kilnΦ4.2x60m
Slope: 4%
Speed: 0.4~4r/min.
Main motor: 450kW12500t/d12Grate cooler
Effective grate areas: ~62.m2
Inlet clinker temp.: ~1350ºC
Outlet clinker temp.: 65ºC+ambient
Outlet clinker size: <25mm
Heat efficiency: >72%113EPfor cooler
Air flow: 315000m3/h
Filter section: ~103.5m2
Inlet airtemp.: 220~350ºC
Dust inlet: <20g/Nm3
Dust outlet: <70mg/Nm3114Gypsum crusherImpact hammer type
Feed size: <500mm
Product size: <25mm
Main motor: 110kW170
No.NameSpecification and SizeQ'tyCapacity(t/h)15Cement millΦ4.2x12.5m
Feed size: <25mm
Product fineness: 3200cm2/g
Speed: 15.8r/min.
Main motor: 3000kW280~85
(each)16ClassifyO-Sepa, N-2500
Capacity: 80~120t/h
Feed rate: max. 360t/h
Air rate: 2500m3/min.
Main motor:130kW217Bag filter for classify
Air flow: 155000m3/h
Filtering area: ~2150m2
Dust inlet: <1000g/Nm3
Dust outlet: <50mg/Nm3
Pressure loss: <1800Pa218Bag filter for classify
Air flow: 95000m3/h
Filtering area: ~1500m2
Dust inlet: <650g/Nm3
Dust outlet: <50mg/Nm3
Pressure loss: <1800Pa119Bulk loader for truckSZ-24~200(each)20Cement packer8-spout rotary2100(each)