JD series seperator is high-efficiency combined raw material special powder sorting machine, which is the latest type of powder sorting equipment developed, combined with advanced powder classify technology to apply the plane eddy current theory to the cyclone type separator. Powder selection efficiency reaches 80-85%, fineness adjustment is convenient and flexible, and the performance is stable and reliable in cement plant.
The main features of the classifier are low energy consumption, large processing capacity, and flexible combination structure: it can be interchanged with the fluidized bed crushing machine to become a crushing classifier, and can be used with a rake mill, a ball mill, a roller mill, etc.
Combine and separate the ultrafine powder, which has the functions of low energy consumption and low pollution; it can be directly connected with dryers, conveyor belts, automatic packaging machines, etc., simplifying the production process and steps. Use of ultra-segmented grades that cannot be graded on common seperating equipment, especially for products that are strictly limited to the largest particles and require a narrow particle size distribution, such as heavy calcium, kaolin, talcum powder, barite powder, paint, Mica, graphite, auxin, aluminum hydroxide, etc. It can classify materials that require extremely strict grain size and meet the requirements of purity and grain shape. Typical materials: copier toner, laser printer powder, mobile phone battery powder, industrial battery powder, etc.
The classification chamber of the cyclone type separator is a cylindrical casing made of steel plate. In classification chamber, the small blades and the spreading disc are fixed together on the vertical axis. The motor is rotated by belt conveyor in the classification chamber. Strong centrifugal force is formed, and gas powder mixture entering the classification chamber is subjected to the centrifugal force.
The large or heavy particles are subjected to centrifugal force, so they are smashed to edge, no longer affected by the centrifugal force. it is collected, and then discharged as coarse powder through coarse powder tube; small or light material is less affected by centrifugal force, hovering inside the grading room, being carried to height by air flow, and moving to the next component along the pipeline It is graded or collected, and speed of the centrifugal force can be adjusted by the frequency converter to adjust speed, so as to separating the materials of the specified granularity.
In recent years, with the improvement of large-scale cloth bag dust collecting technology in China, the long bag dust collector technology used in rotary kiln tail gas treatment of cement rotary kiln with dry process method is increasing da...
Cyclone preheater is one of the core equipment in the new dry cement production process, which is responsible for many functions such as gas-solid dispersion, material heating, gas-solid separation, material transportation and some physical...
Product specification (m) Milling form Transmission form Gear box Motor power (kw) Production capacity (t/h) Total weight (t) Model Speed reduction ratio 1.837 Open flow Brim ZD60 4.5 245 6.5-8 43.8 2.27.5 Open flow Brim ZD70 5 380 8-10 64.8 2.211 Open flow Brim D110 35.5 630 12-13 104.6 2.213 Open flow Brim D110 35.5 630 16-18 114 2.413 Open flow Brim D110 35.5 800 20-23 130.6 2.613 Open flow Brim MFY100 19.5 1000 28-32 158 39 Circle flow Brim D125 41.2 1000 28-36.5 167 311 Circle flow Brim D140 42.8 1250 36-47 180 3.213 Open flow Brim D140 36.5 1600 45-50 225 3.513 Circle flow Brim JDX1000 5.84 2000 60-65 275 3.813 Open flow Central shaft MFY250 16.5 2500 60-62 320 4.213 Open flow Central shaft JQS3550 15.6 3530 85-87 380 4.614 Circle flow Central shaft JSI160-C 14.6 4200 120-135 485
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In the cement production line, we use cement crusher for cement crushing process, then we need cement mill for fine grinding stage. As a kind of cement grinding machine, Cement mill is the equipment used for grinding the hard , nodular clinker from the cement kiln into the fine grey powder that is cement.
Its main function lies in grinding cement clinker (and gelling agent, performance adjusting grinding materials) into suitable particles (by fineness and specific surface area, etc), to form certain particle gradation, increasing its hydration area, accelerating the hydration speed, satisfying the slurry condensation and hardening requirements.
Henan Hongxing Mining Machinery Co., Ltd. is a professional manufacturer of full sets mining equipment including cement mills, stone production line, sand making production line and so on. Besides, we offer the most favorable cement mill price.
Cement ball mill is not only suitable for over-flow grinding, but also applicable for cyclic close-flow grinding together with powder collector. The opportunities and challenges of the cement mill industry co-exsit today, although the overall size of milling machinery manufacturing industry has entered the ranks of the international producing countries, the overall competitiveness and development potential still can't compete with the developed countries. The current domestic high-end users and the basic components for products export mainly rely on imports.
This economic stimulus policy of development can avoid the economic crisis waves, and it makes the development of China's economy and the GDP stabilizing increase steadily. Some basic road and bridge construction of public facilities will bring significant step into the cement ball mill industry which makes cement ball mill industry usher in a new 'spring'. Therefore, the development of cement mill in the future should focus on the revitalization of basic technology and infrastructure components to raise the level of independent development.
India is the world's second largest producer of cement and produces more than 8 per cent of global capacity. Due to the rapidly growing demand in various sectors such as defense, housing, commercial and industrial construction, government initiative such as smart cities & PMAY, cement production in India is expected to touch 550600 million tones per annum (MTPA) by the end of year 2025.
With recent growth and success journey there is also a threat approaching to cement industry that its input cost is increasing. Power cost, fuel cost, raw material cost have doubled up in recent years whereas cement price has not hiked in that fashion. Also 40% of the cement production costs are energy costs out of which more than 60% of the total electricity is used in grinding circuits. In order to survive and sustain in the market they need to increase their profitability which can only be achieved by increasing productivity and reducing power consumption. High productivity and low power costs can be achieved by increasing output, lowering breakdowns and optimizing the energy consuming grinding process.
The objective of the study, is to draw attention to the need of Cement grinding process optimization to minimize power consumption and achieve higher productivity. In the study the advantages of vertical roller mill are discussed over ball mills. VRM construction, its process and parameters which affects the performance and productivity of vertical roller mill are discussed. Also the consequences of variations in parameter explained. With proper optimization of these parameters, the productivity of vertical roller mill can be improved and performance stability can be achieved by addressing root causes.. This study can benefit the organizations using VRM and are not able to utilize its full productivity due to some bottlenecks or constraints.
One of the fundamentals of cement manufacturing is to ensure the right chemical composition of the cement raw mill. A raw mill with a superior fineness and well-controlled chemical composition using as advanced control system can improve the cement quality and define critical cement craft parameters.
Amrit Cement uses the best of raw materials and has an enviable infrastructure supported by advanced technologies to ensure supreme cement quality. Physical and chemical analysis of clinker cement and fly ash with Bureau of Indian Standard Specifications by experts from India and Overseas ensures excellence in its product offerings.
Limestone from mines are brought to plant site and stored in the yard then fed to dump hopper of primary crusher by mixing high-grade and low-grade limestone in defined proportion to meet the quality norms.
The primary crusher is designed with 350 TPH and secondary crusher is installed to reduce the limestone size to further meet the process requirement before reaching the longitudinal stock piles. Longitudinal stacking method is also termed as Chevron Method to improve the consistency while re-claiming.
The stacker and re-claimer are designed for stocking and extraction of limestone and other corrective materials are fed in to respective hopper. Underneath the hoppers weight feeders are installed to make the proportions of desired mixing ratio.
The main raw materials required for manufacturing clinker and cement are Limestone, Clay and Laterite. All the raw materials are stored in respective hoppers and underneath the weight feeders are installed to make the mix proportion.
The above mix proportion is ground in Raw mill at 110 118TPH (Ball mill) to achieve desired fineness and fed into CF silo (continuous Flow silo concreted, capacity 4500MTs) where extraction and filling takes place simultaneously. This kind of system is well-proven for uniform feed to kiln to avoid the variation in burning system.
Our manufacturing facility houses technologically advanced Stacker Reclaimer System for pre-blending and homogenizing the raw mill. This process ensures a fully auto-controlled and homogeneous raw material quality output.
Industrial scale tests were carried out with different types of grinding aids.Effects of grinding aids on grinding and classification operations were evaluated.Effects of the type and dosage of grinding aids on model parameters were examined.Grinding aids had influence on breakage probability, bypass and fish hook.Amine-glycol-polyol mixture was found to be the most effective.
This research focuses on investigating the effects of the three different grinding aids, consisting of a mixture of amine, glycol and polyol in different ratios, on the model parameters of a two-compartment cement ball mill and an air classifier. Within the content of this work, sampling campaigns were organized around a cement grinding circuit and each of the three grinding aids at varying dosage rates were tested. Then the ball mill and the air classifier were modelled by using perfect mixing approach and Whitens equation respectively. The relations between the types and dosage rates of grinding aids and model parameters were examined. The fact that such an examination has not been made previously by using industrial data, which makes this research unique. It was deduced that depending on the chemical composition of grinding aids, their effects on model parameters were varied and ultimately all of them improved the performance of the grinding and the classification operations.
JSPL produces the most eco-friendly cement called the Portland Slag Cement, Portland Composite Cement and Ground-granulated blast-furnace slag under their brand name Jindal Panther Cement in its modern plant, located at Raigarh, Chhattisgarh. This plant operates the most modern Vertical roller mill supplied by Loesche Germany, through a fully computerized process control room.
The cement plants and process engineer (due to training and job title) is frequently asked to examine the big picture in a production/operations environment. This can be a formal request for a diagnostic review or a vague request from top management to see whats wrong or what kind of improvements can be done with production/operations. Operations audit is a procedure that helps the industrial and process engineer determine not only what is wrong, but more importantly, what is right in an operations activity.
Operations audit is the first step in conducting a general and objective assessment of a production/operations area. It is called by many other names, such as diagnostic review, general survey, operations exam, etc. It can be done as a stand-alone project, but is often part of a larger project, such as reducing costs or improving productivity. The technique is based on a logical evaluation of the current factors that control the operating environment.
The audit can be performed by a person or by a team, depending on the complexity of the operation under examination and the need for skills outside the training of the industrial and process engineer. The audit can range from two days to several weeks, depending on the size and complexity of the operation under review.
The audit should result in a concise written statement of the operations strengths and weaknesses and support functions. It should also contain diagrams of the interactive features that contribute to the product or service being provided and any comments on areas for improvement and any specific areas for further analysis. The audit will be based on data, numerous interviews, field visits, and the objectivity and past experience of the systems.
An operations audit should be carried out whenever important changes of a general nature are considered. Some important changes may include: a plant-wide cost reduction effort, the installation of a productivity program, thermal energy efficiency program, electrical energy efficiency program, chemistry and operations strategy, the introduction of new products, changes in the management information system, new plant acquisitions, prior to relocations of plants, etc.
An audit is usually the first step by a management consultant who has been given a broad objective by senior management to improve the profitability of an operation. The consultant may conduct a portion of the audit before the formal proposal is submitted, to ensure that the correct issues are addressed in their proposed work plan. Likewise, the plants process engineer or internal consultant will often find that the audit is a necessary first step in ensuring that they address control issues and not just some of the symptoms.
A variety of tools are used during the conduct of the operations audit and the emphasis will vary based on the complexity of the audit and the time available. One of the most important tools will be the industrial and process engineers ability to conduct the audit as a project, with a written objective, defined tasks, expected deliverables, listing of work steps, and a schedule. If other team members are used, then their efforts will be directed and coordinated as well.
Other important tools are the ability of the industrial and process engineer to conduct meaningful interviews at all levels of the organization, and to document findings and draw clear, concise, conclusions. The handling and gathering of data necessary for the conduct of the audit is a particularly important task, since the time usually allotted to the audit will require not only care in analyzing data, but in making realistic data requests of key departments.
The operations tour and related field trips can be an important source of general information, and the tour can be augmented with product flow charts, equipment location drawings, and facility expansion plans. The observations and answers to key questions during operation tours and related visits can become a useful part of the data gathering stage of the operation audit for confirmation and verification at a later date.
Organization charts, job descriptions, budget plans, financial statements, operations records, and written operating procedures can be useful information to be obtained during the conduct of the audit.
Plant operating and shutdown data need to be collected for the past two or more years. The reasons, duration and frequency to identify the causes in order of severity of the stops are analyzed and their classification:
Plant performance is also analyzed by department. Often, the best performance of a department does not occur at the same time as the best performance of the plant as a whole. If we choose the best throughput times for each department and make them occur at the same time, the throughput of the plant will show a significantly higher level of efficiency. Attempts are being made to make them happen at the same time, which is not an unrealistic goal, as the departments had indeed done so at that level in the past.
Modern dry-process cement plants with an efficient grinding and pyro processing system, typically consume less than 700 kcal/kg-cl of thermal energy and 100 kWh/mt of electrical energy. Older plants with inefficient systems, combined with operational and maintenance failure, tend to have much higher energy consumption. Based on the specific plant conditions and requirements, a general benchmarking is conducted to set goals. Plant audits evaluate the performance of a cement plant against the appropriate benchmark. After a detailed evaluation, recommendations are made for optimizing the plant at three levels of capital investment:
A successful thermal energy management program requires energy auditing as its one of the important procedures. The possible approaches of heat recovery from some major heat loss sources by making a detailed analysis of kiln, raw mill, coal mill and grate cooler. To improve the production process, increase the productivity, decrease energy consumption of the plant.
The main aim of the energy audit is to provide an accurate account of energy consumption and energy use analysis of different components and to reveal the detailed information needed for determining the possible opportunities for energy conservation.
Mills: In the case of ball mills, optimizing the mill load and maintaining the internal parts of the mill will minimize energy consumption. As for the vertical roller mills, the inspection of the internal parts of the mill and the separator, and the adjustments in the operation will bring improvements, both in energy consumption and in increased production.
The evaluation of the process will include chemical data on the input and output streams for the efficiency of the mixture, an annual record of the moisture content and the granulometry of the feed material.
The operations audit can be a beneficial first step in aiding the industrial and process engineer in assessing the appropriate focus for later problem-solving efforts and can be used in a variety of circumstances in most production and operations environments.
ES Processing applies the latest Advanced Process Control (APC) and Artificial Intelligence (AI) technologies proven in other industries to cement process. Our Cement Mill Optimizer (CMO) solution enables cement industries to fully autopilot the cement grinding process for assuring optimal manufacturing conditions. At a high level, this is achieved through our soft sensors that provide near-continuous quality prediction of Blaine and residue every 30 seconds (versus the 1-2 hour lag time required for conventional manual lab testing), and then auto adjust the process Manipulated Variables every 30 seconds based on tailor-made mathematical transfer functions, sophisticated algorithms & MPC rather than subjective operator expertise.
The cement industry is facing new challenges in the form of rising competition, ever-increasing raw material and energy prices, and the need to comply with stricter environmental protection policies challenges that can no longer be faced with the traditional tools used by the industry prior to 2014.
Were helping the cement industry meet these challenges by bringing them into the digital factory/industrial automation revolution with advanced process control and artificial intelligence. Our proprietary solutions are enabling the cement industry to make intelligent use of big data and transform it into algorithms and models that can serve as an autopilot to achieve an unprecedented level of process optimization and enhance quality and productivity and reduce energy consumption.
While Advanced Process Control has proven its capability to maximize production efficiency and product quality, cement manufacturers have been unable to take advantage of it. Continuously measuring the quality of cement manufacturing in real time has been an impossibility since any measuring instruments that might be installed inside a mill would be destroyed. As a result, cement manufacturers have had to rely on a manual sampling process performed on finish product, and then testing the fineness and residue of the samples in the lab. Given the 1-2 hour delay this manual process requires, results are often not available until after production conditions have already shifted or finished product is already in storage silos too late to correct product quality issues.
Adjustments have also been a manual process. Based on test results, the operator must select new combinations of mill fresh feed and separator speed hopping to achieve target fineness, based on their own experience and personal judgement rather than hard data. By implementing CMO autopilot based on hard data rather than operator expertise, our Advanced Process Control solutions empower you to achieve a much higher consistency of product quality and production efficiency.
The inherent imprecision of a manually controlled process usually results in high standard deviation from the quality target and in non-uniform product. Quality suffers. Plus, less frequent larger adjustments that rely on subjective human judgement results in higher-than-necessary electricity usage and greater wear and tear on machinery. ES Processing enables cement mills to leverage data-based APCs to assure consistent product quality.
Data Input: Big data based on historical process data and onsite tests are combined with laboratory data to build a Soft Sensor that can accurately predict fineness and residue based on the full range of performance parameters.
Soft sensors: Our soft sensors are very sophisticated models formed by combining our multiple data-based algorithms adopted from machine learning and based on linear and non-linear identification techniques, PLS, and genetic algorithms. Capable of determining the best correlation between different process parameters and fineness results, theyre able to predict very accurately the Blaine and residue every 30 seconds.
MPC: Our MPC is a highly complex multivariable model based on transfer functions that we build by performing different impulse tests for each mill. Handling complex plant dynamics including long-dead times, non-minimum phase behavior, constraint handling, hierarchical and weighted optimization, and predictive control, its able to adjust process manipulated variables such as separator speed and fresh feed every 30 seconds. Learn More
At each interval, the Soft Sensor predicts the Blaine fineness and the residue value based on several inputs of mill measurements (weight feeders t/h, mill inlet/outlet pressure, bucket elevator Kw, Main Motor Power, Separator speed, Reject, etc.) The Blaine and residue inferred values, are sent as a measurement inputs along with the current Rejects to the Model Based Optimizer or Model Predictive Controller to calculate new optimum setpoints for process manipulated variables such as separator speed and mill fresh feed.
Using this approach, mill operation is consistently pushed to the operational ideal targets due to the continuous prediction of Blaine fineness combined with the optimal adjustments of operating conditions.
Our Cement Mill Optimizer system, is a parallel intelligent solution that acts as an autopilot for the cement grinding circuit. It optimizes the cement quality and increases the overall production by keeping the cement product fineness closer to the ideal targets or in other words keeping a low standard deviation of the final product particles volume. In addition, it decreases cement rejects vis--vis the consistency of the final product fineness, thus reducing specific electrical energy consumption.
What is your greatest challenge? Being able to assure consistent product quality? Achieving greater output with existing equipment? Decreasing staffing and/or electrical costs? Whatever your challenges may be, we can provide an in-depth and upfront ROI analysis of precisely how our Cement Mill Optimizer solution help at no cost to you.
Our Cement Mill Optimizer represents the state-of-the-art in process control for cement manufacturing and can provide the greatest gains in production output and efficiency, product quality and cost savings. However, we offer a long track record of success in the design and engineering, integration and installation, and support and maintenance of conventional DCS & process control systems as well.
What is pre-decomposition technology? The core of the new dry process cement plant is suspension preheating technology and pre-decomposition technology. The clinker pre-decomposition technology refers to adding a new heat source, precalciner, between preheater and cement rotary kiln. When the fuel is injected into the precalciner for combustion, the raw material preheated to about 750 by cement preheater is fed into the precalciner at the same time so that the exothermic process of fuel combustion and the endothermic process of carbonate decomposition in the raw meal is carried out rapidly. Generally speaking, the cement raw meal decomposition rate can reach more than 90% before entering the rotary kiln.
What is precalciner? Precalciner, also known as cement calciner, is a kind of high-efficiency direct combustion solid-gas heat exchange cement equipment. It disperses and suspends cement raw meal powder in airflow, making fuel combustion and calcium carbonate decomposition happen in a short time (generally 1.5 ~ 3 seconds). To some extent, it replaces part of the calcining work of a cement rotary kiln. In the calciner, because the fuel combustion and the material endothermic reaction are carried out at the same time, there is no visible flame, but in a state of low-temperature flameless combustion at 820 ~ 900 .
At present, more than a dozen types of precalciners have been put into use. Although each has its advantages, its characteristics and functions are similar. According to the different movement form of airflow, calciner in cement plant can be divided into four types:
The tertiary air with a temperature of 200 ~ 250 is blown into the air chamber of the fluidized bed calciner by a high-pressure fan and then enters the inner chamber through the air cap so that the fuel and raw materials form afluid-bed.
The preheated cement raw meal (temperature is about 820 ~ 860, not exceeding 860), a certain amount of fuel, and hot air (kiln tail flue gas or tertiary hot air) are fed into precalciner at the same time. After entering the calciner, the fuel and raw meals are dispersed by high-speed airflow and in a suspension state at about 900. The fuel is flameless combustion in the calciner, and the heat released by it makes the calcium carbonate in the raw meal decompose at a high speed through a convection heat transfer and radiation heat transfer. Generally, this decomposition process can be completed in a few seconds, and the decomposition rate of the whole raw meal is as high as 85% ~ 95%, forming an efficient operation mode of combustion, exothermic, endothermic, and decomposition at the same time.
Precalciner forms the clinker calcining system in the new dry process cement plant together with cement preheater, rotary kiln, and cement cooler. In addition to cement calciner, AGICO also provides other high-quality clinker calcination equipment, such as cyclone preheater, cement rotary kiln, grate cooler, rotary cooler, etc.
AGICO Group is an integrative enterprise group. It is a Chinese company that specialized in manufacturing and exporting cement plants and cement equipment, providing the turnkey project from project design, equipment installation and equipment commissioning to equipment maintenance.