Limestone Rotary Kiln for Clinker Production Line Plant

Product Description

Limestone Rotary Kiln for Clinker Production Line Plant 
 

 

Cement Production Plant Rotary kiln is a preprocessing device used to raise materials to a high temperature (calcination) in a continuous process.Materials produced using rotary kilns include: Cement, Lime, Refractories, Metakaolin, Titanium dioxide, Alumina, Vermiculite,Iron ore pellets, etc. Cement Production Plant Rotary kiln is a cylindrical vessel, inclined slightly to the horizontal, which is rotated slowly about its axis. The material to be processed is fed into the upper end of the cylinder. As the kiln rotates, material gradually moves down towards the lower end, and may undergo a certain amount of stirring and mixing. Hot gases pass along the kiln, sometimes in the same direction as the process material (co-current), but usually in the opposite direction (counter current). The hot gases may be generated in an external furnace, or may be generated by a flame inside the kiln. Such a flame is projected from a burnerpipe (or "firing pipe") which acts like a large bunsen burner. The fuel for this may be gas, oil or pulverized coal. Rotary kiln is often compared to an industrial sized oven which is designed to withstand extreme temperatures as needed for the smelting process of all types of hydraulic cement. Small Scale Limestone Rotary Kiln Cement Clinker Production Line Plant

Small Scale Limestone Rotary Kiln Cement Clinker Production Line Plant Working Principle
After precalcining the raw meal will be fed into the kiln from the preheater for burning. Because of the inclination and rotation of the kiln, the material within the kiln will have a combined movement not only rolling circumferentially but also moving axially along the kiln from the higher end to the lower. After heating, calcining, sintering and cooling in the kiln, the clinker is formed and is then sent into the cooler. Fuel is blown into the kiln from the outlet of the kiln by the burner and burns in the kiln. The raw meal is heated by the hot energy and formed into clinker. The hot air formed after the heat exchange with the material enters the preheater system and finally vents into the atmosphere through the chimney.

 
 


1.Crushing and Pre-homogenizing:
 (1) Most of the raw materials, like limestone, clay, iron ores, and coal, should be crushed before their pre-homogenization. Limestone is the primary material in this line, and due to its large particle size and high hardness, its good crushing plays an important role in the whole line. Special stacking and reclaiming technology has been used in the pre-homogenizing process so that raw materials can be better primarily homogenized.
 (2)Raw material homogenizing: raw materials pre homogenizing is in the material piling up, by stacker to incoming raw materials continuously in a certain way piled material layer as much as possible parallel to each other, the upper and lower overlap and the same thickness. When, in the direction perpendicular to the material layer, as far as possible at the same time, cut off all material layer, in turn cut, until taken the end, namely "tile straight". The raw material yard has the functions of storage and homogenization
 
2.Raw material preparation:
 (1)Raw materials: raw ingredients with limestone, sandstone, iron ore, four flyash base ingredient database (or other special materials library), base bottom are respectively provided with a weighing feeder, quantitative various materials are given according to the requirements of the production process ratio. By the belt conveyor into vertical mill  system for grinding.
 (2)Raw material grinding: the material through the lock feeding device by a feeding chute to disc center, under the action of centrifugal force was thrown to the edge of the grinding disc delivered by grinding roller rolling mill, the crushed materials from the disc edge overflow, is from the nozzle speed upward with the hot air flow drying up, according to the airflow velocity different, part of the material was taken to the air high efficiency separator, coarse powder after separation, returned to the grinding table, re grinding; fine powder qualified with gas out flow after grinding and increasing dust mixed wet tower and electric dust collection, through the chute, the bucket is sent to the raw meal homogenizing silo within elevator and storage.
 
3.Raw meterial homogenizing:
Raw meal in a downward landed, with air agitation, gravity, produce "funnel effect", try to cut the multilayer surface, fully mixed. The use of fluidized air different, make the base surface occurred in parallel streams of different sizes of expansion effect, some regional discharge, some regional flow, so that the base surface is generated within the tilt, radial mixing. In the production process of cement raw meal composition, stable pit entry is the stability of clinker burning premise of thermal system, raw meal homogenizing system plays a stable raw ingredients into the cellar of the final control action.
 
4.Pre-heater and pre-calciner
The raw material preheating and partial decomposition of the pre heater to complete part function, instead of the rotary kiln, the kiln to shorten the length of back, at the same time in the furnace to the accumulation state of gas feed heat transfer process, moved to the inner suspension pre heater condition, the raw hot gas can be exhausted with the kiln are fully mixed, increases the gas material the contact area, fast heat transfer speed, high heat exchange efficiency, improve the production efficiency of kiln system, reduce the heat consumption of clinker burning purpose.
(1)the main function is to make full use of the pre heater kiln and pre calciner exhaust waste heat heating the raw material, the raw preheating and partial decomposition of carbonates. In order to maximize the efficiency of heat exchange between the solid and gas, to realize high quality, high yield, low consumption of the burning system, must have the solid gas uniform dispersion, heat quickly and efficient separation of the three functions.
(2)pre decomposition: pre decomposition technique is a technical leap in cement calcining process. It is between the pre heater and calciner and rotary kiln kiln tail added by rising flue, a fuel injection device, an endothermic process to make fuel combustion exothermic process and raw material of carbonate decomposition, in the decomposition furnace with suspended or fluidized state quickly, so the raw meal decomposition rate increased to 90% the above. The original is in rotary kiln carbonate decomposition tasks, moved to the decomposition furnace; fuel mostly from the calciner to join, in part by adding less kiln head, reduce the heat load of the kiln calcining belt, prolonging lining life, is conducive to mass production; because of fuel and raw material mixing, fuel the heat of combustion of timely delivery to the material, so that the combustion, heat transfer and carbonate decomposition process optimized. So it has high quality, efficient, low consumption and a series of excellent performance and characteristics.
 
5.Clinker burning:
The raw material is completed in the cyclone pre heater in preheater and precalciner, into the rotary kiln in the clinker burning. In rotary kiln is further decomposed rapidly and carbonate solid phase reaction of a series of cement clinker, generate AC3, AFC4, SC2 and other minerals. With the material temperature rise near C01300, AC3, AFC4, SC2 and other minerals will become liquid,dissolved in liquid SC2 and CaO reaction to generate a large amount ofSC3 (clinker). The clinker burning, the temperature began to decrease. Finally by the cement clinker cooling machine high temperature clinker cooling rotary kiln unloading to storage the set temperature for storage, sensible heat and recovery of high temperature clinker, improve system heat efficiency and the quality of clinker.
 
6. Cement mixing station:
Cement clinker, gypsum, station auxiliary materials storehouse, the guideline is respectively provided with weighing feeder, will give quantitative various materials according to the set ratio. Library side of clinker proportioning librarythe other with clinker bulk facilities, for external use of clinker. Material feeding metering equipment according to the proportion of discharge, by belt conveyor sent to the ball mill for grinding.
 
7.Cement grinding:
Cement grinding is the final process of cement manufacture, but also the most power hungry process. The main materials through the cement clinker (and gelling agent, performance adjustment material etc.) grinding to appropriate particle size (in fineness, specific surface area, such that the outlet material) by the bucket elevator into high efficiency separator in the sorting, coarse powder grinding to grinding, cement products by the air box. Pulse bag type dust collector to collect after by air transport chute, bucket elevator sent to a repository.



Dry process cement production line (25-200t/d)Configuration
 

Clinker capacity Equipment Parameters		25t/d	50 t/d	100 t/d	150 t/d	200 t/d
Rotary kiln	Specification	Φ1.4×33m	Φ1.6/1.9×36m	Φ2.2×45m	Φ2.5×50m	Φ3×60m
	Capacity	1t/h	2t/h	4t/h	6t/h	8t/h
	Calcination Temperature (ºC)	1450	1450	1450	1450	1450
Raw mill	Specification	Φ1.2×4.5m Open circuit	Φ1.5×5.7m Open circuit	Φ1.83×6.1m Open circuit	Φ1.83×6.1m Closed circuit	Φ2.2×6.5m Closed circuit
	Capacity	1.7t/h	4.5t/h	9t/h	12t/h	16t/h
	Motor power	55kW	130kW	210kW	210kW	310kW
Cement mill	Specification	Φ1.2×4.5m Open circuit	Φ1.5×5.7m Open circuit	Φ1.83×6.1m Open circuit	Φ1.83×6.1m Closed circuit	Φ2.2×6.5m Closed circuit
	Capacity	1.4t/h	3.5t/h	6.5t/h	8t/h	12t/h
	Motor power	55kW	130kW	210kW	210kW	310kW

 
New dry process cement production line (300-1500t/d) configuration

Clinker Capacity Parameters		300t/d	700 t/d	1000 t/d	1500 t/d
Pre-heater	C1	2-Φ2500	Φ3500	Φ4800	2-Φ4000
	C2	Φ3600	Φ4800	Φ4800	Φ5800
	C3	Φ3600	2-Φ3700	Φ5200	Φ5800
	C4	Φ3600	Φ4800	Φ5200	Φ6200
	C5	Φ3600	Φ4800	Φ5200	Φ6200
Pre-calciner	Specification	Φ2200	Φ2800	Φ4800	Φ5200
Rotary kiln	Specification	Φ2.8×44m	Φ3×48m	Φ3.2×50m	Φ3.5×54m
	Capacity	12.5t/h	30t/h	42t/h	63t/h
	Calcination temperature (ºC)	1450	1450	1450	1450
Raw mill	Specification	Vertical roller mill Φ1700	Dry mill Φ3.2×7+1.8m	Dry mill Φ3.5×10m	HRM2800 Vertical roller mill
	Capacity	30t/h	50t/h	85t/h	130~160t/h
	Motor power	400kW	1000kW	1250kW	1250kW
Cement mill	Specification	Φ2.4×13m Open circuit	Φ3×11m Closed circuit	Φ3.2×11m Closed circuit	Φ4.2×13.5m Closed circuit
	Capacity	22t/h	42t/h	64t/h	95t/h
	Motor power	800kW	1250kW	1400kW	3550kW

FAQ:

Q:Payment                                                                                                                                                          
 A:30% by TT as deposit on signing the contract, 70% by as final payment of balance after the client's satisfactory inspection of the equipment prior to the goods leaving the factory.

Q: What about Warranty? what will we do if the machine is broken down                 
A: The warranty period for all of structural and mechanical equipment is one year. The warranty period for all electric motors is half one year. Wear parts are not covered by warranty unless the component part is found to be flawed.
 
Q: What should we need to do for if we want to get a best quotation                     
A: Hi, if you want us recommend a suitable type for you ,please let us know  as follows:
1).the capacity (tons per hour )
2).feed size
3).output size

Q: What could you help me to do for the business                                                                                
A: Many thanks for your trust , we can provide you with proposal chart for complete production lines,spot inspection and operator traning according to your demands and the conditions of applied spot , we can help you choose the right equipments ,drilling rig ,loader ,trucks ,excavators and so on for rotary washer for sand washing.
 
Q:Delivery time                                                                                                       
A: Standard delivery time is 30 days from receipt of deposit,the special required machine is 45 days.