Brief Summary of a Turnkey Cement Plant Project - Chanderpur

Posted by Chanderpur Group on January 21st, 2021

Cement manufacturers usually set up turnkey projects which cover every step of the process. The essential components of a turnkey cement project include equipment for mining, crushing, grinding, blending, calcination, pyro-processing, and storage. A rotary kiln is utilized for calcination by treating the raw materials at high temperatures. If you are looking forward to getting state-of-the-art equipment and material for a rotary kiln cement project, understanding a variety of things is important. Here’s what you need to know:

Raw Material

The raw material includes a mixture of calcium, silicon, aluminum, clay, slate, iron ore, etc. The raw material is crushed and grounded using equipment such as ball mills, rod mills, air classifiers, etc. There are dry and wet methods of preparing the raw material which only differs in the aspect that for the wet method, water is added during raw material preparation.

Raw Meal

The raw material is fed to raw mills which contain a drying chamber and a grinding chamber. Upon drying by hot gases from the preheater, the raw material is sent further for fine grinding. The course material left from grinding is recirculated for the further fineness of particle size. The fine particles mixed with hot gases are entered into a cyclone for separation. The raw meal thus prepared is fed to the preheater for pyro-processing.

Rotary Kiln

The next step in cement production consists of moving the raw meal through a rotary kiln at a temperature as high as 1400 ?C. The rotary kiln is about 200 meters long and 6 meters in diameter. One end of this tube has a heating source to reach the specified temperature. The raw feed is entered through one end and is released from the other in the form of solidified mass known as clinker which maybe 1 to 25 mm in size.

Clinker Storage

The clinker thus produced is cooled using cooler fans and stored in silos. The dome-shaped may be approximately 35 meters in diameter. Clinker storage is required as improper handling of clinker may be an environmental concern. Powdered cement is then produced by grinding the clinker with gypsum, sulfur, etc. using ball mills. The cement is packed into bags following this step.

Equipment

A sustainable cement turnkey project is within reach of a mining area and is fully equipped with every piece of machinery required from beginning to the end of the manufacturing process. A wide range of equipment such as mills, crushers, grinders, separators, kilns, etc. is required to carry out each step. Apart from this, there may be multiple options for one specific process depending upon the purpose.

Energy Requirement

The primary consumption of energy is for running the rotary kiln which may be operated using fuel such as coal. The electricity is used mainly for operating the crushing and grinding machines. As a general idea, about 50% cost of production is spent on energy sources including fuel and electricity.

Environmental Concerns

A turnkey rotary kiln cement plant is required to take the environmental emissions into account. Nitrogen oxides, sulfur oxides, and dust are the primary candidates in this category. Apart from this, noise and odor emissions are also to be considered.

Conclusion

A turnkey rotary kiln cement plant is beneficial for consumers as such operations provide a constant supply of cement at affordable prices. A turnkey plant is a high-maintenance project due to the complexity of the operation, therefore, must be built on the foundation of strong teamwork and expertise.