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Cement equipment refers to the cement making machines that are applied to the cement manufacturing plant. Equipment used in the cement process includes kilns, crushers, grinders, and blenders. Kilns are used to create the heat necessary to turn the raw materials into clinker. Crushers are then used to break down the clinker into powder form. Grinders help reduce the material to even smaller sizes. Finally, blenders are used to mix all of the components together to create the cement.
Advantages of Clinker Mill
Particle Size Reduction
The milling process reduces the clinker’s particle size, which is essential for enhancing the cement’s performance. The finer the particle size, the better the cement’s properties, including strength, setting time, and durability. Cement with smaller particle sizes also offers better surface area coverage, making it easier for the material to bond and create a stronger structure.
Consistent Quality
Clinker mill ensures that the final product is consistent in terms of quality. The milling process enables manufacturers to control the particle size distribution and produce cement with a specific surface area. This helps to ensure that every batch of cement produced is of the same quality, which is essential for construction projects.
Energy Efficiency
Clinker mill is an energy-intensive process that requires a significant amount of energy to operate. However, with the advancement of technology, modern cement mills are designed to be more energy-efficient. By using high-pressure roller mills, vertical roller mills, or ball mills with high-efficiency separators, manufacturers can reduce their energy consumption while still producing high-quality cement.
Cost Savings
Clinker mill can also help to reduce production costs. By controlling the particle size and surface area of the cement, manufacturers can use less clinker and more additives to produce the same amount of cement. This can help to reduce the overall cost of production, making cement more affordable for consumers.
Six Crucial Cement Equipments In Cement Factory
Cement Rotary Kiln
Cement rotary kiln is the core equipment of cement plant, mainly responsible for clinker calcination, which can be used both in dry process cement production line and wet process cement production line. It is usually placed horizontally and at an angle to the ground, forming a state of one end high and one end low. The kiln body rotates slowly under the drive of the engine. And the fuel is injected from the kiln head and burned in the kiln to give off heat. Raw materials enter the kiln from the high end and move toward the low end in the slowly rotating kiln body. In this process, chemical and physical reactions are generated through high-temperature heating, and then the clinker is finally formed.
Shaft Kiln
The shaft kiln is also called a vertical kiln. Compared with cement rotary kiln, it is a standing and non-rotating cylindrical cement kiln, which can also be used in wet cement production line and dry cement production line. The interior of the shaft kiln is divided into preheating zone, calcination zone, and cooling zone from top to bottom. Raw materials enter the kiln from top feeding port and move down by their own weight. In this process, they exchange heat with the hot gas and produce chemical and physical changes, finally form clinker. The shaft kiln is not so widely used in cement plant as rotary kiln, but its structure is simple, the space occupation is small so the investment is relatively low. Besides, it has a long service life and can produce cement of stable quality, which is a common clinker calcination machine in cement plants.
Cement Mill
A cement mill is just a general term for clinker grinding mill. It is a kind of grinding equipment that used to grind the calcined cement clinker then make them reach the particle fineness requirement of the finished cement product. It is the core equipment of the last step in the cement production process. The cement mill we usually used in cement plants includes cement vertical mill, cement ball mill, cement roller press, etc.
Cement Vertical Mill
At present, most of the cement vertical mills in the market merge crushing, drying, grinding, and grading transportation into a single. They mainly use the grinding disc and rollers to compress clinker particles for realizing the reduction of grain size with small dust pollution. The cement vertical mill has become the first choice of many cement plants.
● The system is simple, the layout is compact, and it can be arranged in the open air so that saves a lot of investment cost.
● Small vibration, low noise, the whole equipment is sealed. The system works under negative pressure with no dust spillover, meet the national environmental requirements.
● The grinding roller directs grind materials on the grinding disc. It saves 30% – 40% energy consumption compared with the ball mill grinding system.
Cement Ball Mill
Cement ball mill is a kind of horizontal cylindrical rotary grinding device. Through a continuous rotation, the grinding media (grinding steel ball) in the cylinder body is thrown into the air and then falls to hit the clinker to realize the reduction of the clinker particle size.
● Strong adaptability to physical properties of materials (particle size, moisture, hardness, etc.).
● The full hydraulic operation, easy to use, easy to achieve automation, 40% reduction in energy consumption.
● The circular vibrating screen is used to form a closed-circuit system to realize the circulation grinding of materials. The crushing efficiency increased by 15%.
● It can adapt to different operation requirements: dry or wet cement production, open or closed system, single pulverizing or pulverizing and drying operations.
Cement Roller Press
The cement roller press is a new kind of cement mill. It is usually used as a pre-grinding system to replace some functions of the ball mill so that the output of the ball mill can be increased by 30-50%. At the same time, it can also be singularly used in cement plant as a clinker grinding machine. In principle, it uses two rollers to extrude clinker to reduce the particle size.
● The roller press is simple in structure, small in size and light in weight. It occupies little space in the workshop and can save civil construction investment.
● High grinding efficiency and energy- saving.
The whole structure of clinker mill mainly includes feeding device, rotating bearing, compartment plate, lining plate, barrel, discharging device and driving device.
As an expert in the clinker mill manufacturers, the clinker mill we produced adopts the advanced internal powder selection special compartment structure, which can effectively accommodate the storage of small-sized grinding media, thus greatly improving the overall grinding efficiency of the cement mill. Increased production capacity while achieving the goal of reducing energy consumption.
According to the needs of different customers, there are two types of clinker mill: open-flow mill and circular-flow mill.
The φ3.8×13 clinker mill with double-sliding structure solves the problem of the similar product “the discharge end slide bearing temperature is too high to operate continuously”, which ensures the equipment can run continuously and stably for a long time and makes a new technical breakthrough in the field of double slide ball mill.
When Operating The Clinker Mill, You Need To Pay Attention To The Following Points
Ensure that the inlet and outlet of the mill are unobstructed to avoid the normal operation of the mill being affected by material blockage.
Regularly check the transmission device of the mill to ensure that it works properly, to avoid affecting the operation of the mill due to transmission device failure.
Regularly add lubricating oil to the mill to ensure that the rotating part of the mill is fully lubricated to prolong the service life of the mill.
Pay attention to the rotating speed of the analyzer to avoid too high or too low rotating speed, which will affect the grinding effect and fineness control.
Clean the mill and analyzer in time to avoid the residual material affecting the grinding effect and equipment cleaning.
Regular maintenance and overhaul of the mill to ensure long-term stable operation of the mill.
When loading the mill with empty warehouse, add materials first and then add the ceramic balls.
Cement industry has been forced to eliminate the ball mill below 3 meters, so all enterprises in the grinding ball assembly mill, are using electric hoist, lifting and unloading, the drop is more than 3 meters. Ceramic grinding ball is discharged into the bin with cast steel lining plate, which will impact the lining plate and cause different degrees of micro-cracks inside the grinding ball, affecting the service life. Therefore, empty warehouse loading grinding should first add 2~3 tons of bulk cement, in order to ease the unloading.
Ceramic grinding ball should not be used in the first bin of ball mill.
Although most of the present cement grinding system adopts pre-crushing equipment, which reduces the particle size of the grinding material a lot, when the particle size of the grinding material is 25mm, the first bin of the ball mill still needs the grinding ball to be in the throwing state, mainly for impact crushing effect, crushing the bulk material into new "grains". At this point, the grinding ball is not only subjected to a strong "reaction force ", but also inevitably hit the mill inside the dense cast steel lining, compartments and other components. Therefore, such conditions are not suitable for ceramic grinding balls with limited toughness. Otherwise, a higher rate of breakage will occur.
Shorten the "empty material area" behind the silo board as much as possible.
The cement ball mill cylinder is equipped with a double compartment plate, the front layer is composed of a number of grate plate assembly, the second layer is composed of no grate slot blind plate and the center discharge cone (vent). The fine particles in the front bin can flow into the sandwich layer of the compartment through energy seam, and then pass through the back layer, which rises from the hoisting plate on the board and falls to the outer wall of the middle unloading cone and slides to the next bin (tail bin). The inner wall of the unloading cone is the central vent of the mill. Under the action of the wind speed in the mill, the fine particles falling from the outer wall of the unloading cone will be blown away, leaving a distance from the compartment plate to form a "grinding ball"· the "empty material area" with more and less materials directly affects the effective utilization rate of this warehouse. If this bin is filled with ceramic grinding ball, it will cause collision and wear between grinding ball, grinding ball and steel lining plate, shorten the service life of grinding ball, speed up the rate of broken ball. Therefore, before using ceramic grinding balls, increase the length of the feeder plate as much as possible to make it close to the cylinder, so that the fine particles entering the sandwich layer of the compartment can be quickly picked up and more materials fall into the next bin. At the same time, the central control operation can properly reduce the wind, reduce the central wind speed, shorten the length of "empty material area", reduce the "self-damage" loss of ceramic grinding ball, and increase the effective work.
Adjust operation habits to prevent "empty mill" operation
When ball mill cement grinding system is used in steel ball and steel forging, it is a common operation habit to "add material after starting empty grinding and stop grinding after discharging empty material". However, using ceramic grinding balls, these habits become the most common "killer" of "broken balls". The collision and friction between porcelain ball and steel lining plate will produce numerous micro-cracks, which will accelerate the expansion of cracks and finally lead to grinding ball cracking. Porcelain ball cracked surface, like a sharp edge, split to other grinding ball, no material block and buffer, cause grinding ball more extensive damage, a "ball war" will quickly spread.
Cement Production Line Usually Includes the Following Main Parts
Crushing and pre-homogenization
Firstly, raw materials such as limestone and clay are crushed into small particles by crusher for further processing. Pre-homogenization equipment is then used to adjust the composition and proportion of raw materials to ensure the quality and stability of raw materials.
Homogenization of Raw Material Preparation
This step mainly involves mixing and grinding the crushed raw materials to form a homogeneous raw material. In dry production, the raw material is ground in a dry state; while in wet production, the raw material needs to be mixed with water to form a slurry first, and then ground.
Preheating decomposition
After the raw material is prepared, it needs to be heated to a certain temperature by means of a preheater to partially decompose it. This process removes some of the moisture and also helps in the subsequent firing process.
Firing of cement clinker
Preheated raw meal is fed into the kiln for high temperature firing. In dry production, the raw meal can be directly fed into the dry kiln; in semi-dry production, the raw meal needs to be added with an appropriate amount of water to make raw meal balls and then calcined; in wet production, the raw meal slurry is directly fed into the wet kiln, or the raw meal slurry prepared in the wet process is dewatered and then made into raw meal blocks for calcination.
Cement grinding and packaging
The clinker after firing needs to be further ground by the grinding equipment to form cement powder, and finally packaged through the packaging machine, ready for sale.
The material enters from the feed pipe and is scattered into the rising airflow through the dispersion plate. The pulverized medium debris in the material overcomes the falling resistance of the rising airflow under the action of gravity and is discharged through the slag discharge outlet. The airflow carrying the powder rises to the grading section and enters the rotor through the guide vanes for grading. The guide vane can make the flow and powder particles rotate, pre-grade, and capture the coarse particles thrown out by the rotor, and also make the speed of the flow evenly distributed on the height of the whole rotor. The coarse particles trapped by the guide vane fall on the cone of coarse powder and are discharged by the outlet of the coarse powder, while the fine particles and airflow enter the middle of the rotor through the rotor blade and are sent to the collection device by the outlet of the fine powder.
How to Maintain and Clean Cement Equipment for Optimal Performance
Routine Maintenance Tasks
Regularly inspect all parts of the cement equipment and look for signs of wear, cracks, or other damage that could affect performance. Be sure to lubricate any moving parts to reduce friction and help prevent corrosion. Maintain the integrity of your cement equipment by checking to see that all bolts and connections are tight. Loose components can lead to instability and pose safety risks over time.
Scheduled Servicing
Follow a regular servicing schedule with qualified technicians so they can perform comprehensive checks and maintenance tasks that go beyond your routine upkeep. During scheduled servicing, technicians should inspect all components and replace any that show signs of wear. This preemptive approach helps prevent unexpected failures and further extends the operational life of your cement equipment.
Cleaning Procedures
Accumulated cement and dust can cause blockages and reduce efficiency, but by consistently cleaning the equipment, you will reduce this buildup and improve the equipment’s functionality. Different components require different cleaning methods. For example, high-pressure air or water can be used to clean exterior surfaces, while specialized tools may be needed for internal parts. It is important to select the right cleaning agents; so use products that are safe to use on the equipment by checking the materials used on its different parts.
Safety Considerations
Safety should always be a priority during maintenance and cleaning and adhering to established protocols helps prevent accidents and injuries. Make sure to wear appropriate personal protective equipment, such as gloves, goggles, and protective clothing while handling equipment and chemicals so you can maintain a safe work environment.
Documentation and Record-Keeping
Keep detailed logs of all maintenance and cleaning activities and document performance metrics and any issues that crop up. Having this log can help you and others identify patterns that may indicate underlying problems with the cement equipment. Accurate records also provide proof that you have maintained the equipment according to the required standards.
Continuous Improvement
Regularly review and update maintenance and cleaning procedures to ensure they are as effective and efficient as possible. Get feedback from those who operate the equipment daily so you can gain insight into potential improvements and optimizations. Maintaining and cleaning cement equipment is crucial for ensuring its optimal performance, safety, and longevity. By prioritizing these practices, you can prevent breakdowns, extend equipment lifespan, and enhance project efficiency.
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Ultimate FAQ Guide to Cement Equipment
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