Cement production line is the production line composed of a series of cement production equipment, mainly involving Crushing stage, pre-homogenization, raw material preparation and homogenization, preheating and decomposition, cement clinker calcination, cement grinding, packing and so on.

Chaeng can provide the whole cement production line turn-key service (from design, manufacturing, installation, debugging and capacity and standard reaching) depends on years of experiences in equipment manufacturing and project construction. The technological process of turn-key service has been continuously optimized in order to achieve energy saving, reducing consumption and high efficiency

Raw material crushing

During the cement manufacturing process, most of the raw materials vitally need to be crushed, such as limestone, clay, iron ore, coal etc. However, among those raw materials, the limestone crushing plays a very important role for cement manufacturer, not only because of its largest consumption amount, but also its higher hardness and bigger grain size.

gypsum                                    limestone                                       iron ore

Raw material preparation & Pre-homogenization

During cement manufacturing, for 1 ton Portland cement, it will takes 3 tons materials (including the raw materials, fuel, clinkers, mixtures and gypsum). According to the statistics, in dry cement production line, the power taken by grinding occupied more than 60% of the total power, including over 30% for meal grinding, about 3% for coal grinding and about 40% for cement grinding. Therefore, choose the suitable equipment and technology process, right operation and control system have great meaning to the quality control and power reduce.

Great Wall Machinery is a professional cement equipment manufacturer. We can provide the equipment of meal grinding, clinker grinding and coal grinding. In many customers’ cement production line EPC projects, we equip the GRM series vertical roller mill designed and manufactured by us. Compered withball mill grinding system, the vertical roller mill grinding system has the advantages like smaller occupied area, lower civil cost, higher effective grinding, lower power consumption, lower metal consumption and lower noise etc.

Preheating and decomposition

Preheating and part of the decomposition of The raw materials are done by preheater, Instead part of rotary kiln, To shorten the length of kiln, At the same time, the heat transfer process of kiln are Moved to the preheater, Raw meal will blended with hot gas which discharged from kiln, Increase the contact area, Accelerate the heat transfer speed, High heat exchange efficiency, Improve the production efficiency of the kiln system, and Reduces the clinker calcining heat consumption

Heat transfer are happened in the entrance of the pipe, the Raw Material which was feed into preheater pipe, also get separated by the impact of high speed rising air

When the air flow into cyclone cylinder with powder, forced to do rotary flow In the annular space, and down while rotating movement, from the cylinder to the cone, can be extended to the end of the cone, then turned up the rise, then out from the exhaust pipes.

The emergence of precalcining technology is a technological leap of Cement calcining process, add decomposition furnace between the preheater and rotary kiln, set a fuel injection device, Make the fuel combustion heat release process and endothermic process of carbonate decomposition of raw meal, proceeds rapidly, Let the decomposition rate of raw meal increased to 90% or even more. Let the carbonate decomposition task which were Conducted in rotary kiln, move to the decomposition furnace, most fuel joining in from decomposition furnace, a few join from the kiln head，Reduce the heat load of kiln calcining zone，extend the working life of the lining, Conducive to large-scale production; Fuel and raw material mixing evenly, fuel combustion heat passed to the materials timely, the combustion heat and carbonate decomposition process was optimized, Thus has excellent quality and efficient of low consumption, and a series of performance and characteristics.

Cement clinker calcination

After preheating and precalcining , raw material will be burned into clinker by rotary kiln.Carbonate in the rotary kiln decomposed rapidly with a series of solid-phase reaction, and minerals of the cement clinker generated. As the material’s temperature rise, the minerals will become liquid, dissolved in liquid phase to generate a large amount of clinker. After raw material burned into Clinker, temperature began to fall. Finally, the cement clinker cooler will cool the high temperature clinker discharged from the rotary kiln to a degree that can stand by the downstream conveyor, storage silo, cement mill. At the same time, it recycles the sensible heat of high temperature clinker, improves the thermal efficiency of the system and quality of clinker.

Cement grinding

Cement clinker grinding is the end process of the cement manufacturing , is also the most power consumption process. Its main function is grinding the cement clinker (and gelatinizer, performance adjustment material, etc.) to appropriate particle size (fineness against specific surface area), to form a certain size distribution, increase its hydration area, accelerate the hydration speed and satisfies the requirement of setting and hardening cement paste.

The Great Wall machinery’s cement turnkey project line for the customer is equipped with our own cement vertical mill with advantages of simple process, easy to control, can use large amounts of waste gas from the preheater kiln tail, save energy consumption, high grinding efficiency.

Packing & storage

The cement is housed in storage silos, from where it is hydraulically or mechanically extracted and transported to facilities where it will be packaged in sacks or supplied in bulk. In either case, it can be shipped by rail car, freighter truck or ship.

Packing system adopts a cement packing line produced. This system is arranged with packing machine, electric calibration scale, bag destroyer and bag air remover, and its strong points include high weighing precision, good sealing performance, little flying dust, high automation and easy operation.

There are many dust collection points in the packing system. This system is installed with four dust collectors , which collect dust from each dust collection point. The collected cement dust is returned to bucket-type elevator through screw conveyer .

Choose chaeng advantages

1. Our combined EPC and O&M solution can give you the return without the risk.

As a global supplier of grinding system, Great Wall are experienced in the product design, process control and energy efficiency management. We are confident to provide a high quality, integrated grinding solutions for the customer of cement industries.

2. The advantage of the fastest delivery.

Our company possesses the large scale Steel Casting Room and very great Mechanical Processing ability for undertaking all kinds of casting parts or equipment orders. With the assurance of the high quality, a vertical roller can be promised to be delivered in 4-6 months. Meanwhile, the production cycle for a complete set of production line is as soon as 10-12 months.

3. Choose the decelerator, bearing and hydraulic key element of brands both in home and abroad to guarantee the sound operation of equipment.

4. Compliance with latest emissions standards and environmental regulations

Negative pressure system is utilized to reduce the chances of dust escaping outside the cement vertical roller mill, resulting in dust concentration less than 1 mg/m³ in the surrounding atmosphere. This assure the DUST EMISSION conform to the "Emission Standard of Air Pollutants for Cement Industry" (GB4915-2004); the NOISE CONTROL conform to the "Emission standard for industrial enterprises noise at boundary" (GB12348-2008).