Silicate cement production technology is typical in cement production. limestone and clay are main materials. After crushed, dosed and ground, the limestone and clay are made into raw materials, then come into cement kiln to be roasted into clinker aggregate. The clinker aggregate with right amount of gypsum( mixed material or admixtures can be added sometimes) is ground so that the silicate cement can be produced.
Accorrock to different raw material preparation methods, cement process production can be divided into dry method (Inclurock semi-dry method) and wet method (Inclurock semi-wet method).
① Dry cement production process: the raw materials are dried and ground, or the dried raw materials come through raw materials powder then the powders are sent into dry kiln to be roasted into clinker. But the raw materials powders can be mixed into raw materials balls with some water added. The materials balls are sent into Lepol kiln to be roasted into clinker, which is called semi-dry method and is belonging to dry production method.
② Wet cement production process: the raw materials with some water is ground to become raw materials slurry, then the raw materials slurry is sent into wet kiln to be roasted into clinker. Or the raw materials slurry is dehydrated and is made into raw materials blocks, the raw materials blocks are sent into kiln to be roasted into clinker, which is called semi-wet method and is belonging to wet production method.
The main advantage of dry production is low heat consumption(heat consumption of dry kiln clinker with preheater is 3140-3768J/kg). The disadvantages are that: raw ingredients are not uniform, workshop dust is too much and the power consumption is too high. The wet cement production process features with simple operation, raw ingredients are easily to be controlled easily controlled raw ingredients, good products quality, convenient pulp transportation, less workshop dust, etc. But the disadvantage is high heat consumption ( clinker heat consumption is 5234-6490J/kg).
A set of cement production process flow, can be classified into three procedures: raw material preparation, clinker calcining and cement ground.
The raw materials can be classified into dry process and wet process. The dry process is using closed-circuit operating system. The raw materials are ground by cement mill then the fine powders are dressed by powder concentrator. The coarse powders come back to the cement mill to be ground again. Most of using materials are dried and ground in Grinding machine. The cement equipments are tube mill, medium discharged mill and roller mill, etc. The wet process usually uses tube mill and ball mill. The materials come through cement Grinding machine for only one time and won't come back again. This is an opening system but there also is closed system with classifier or bow screen.
The cement devices for clinker calcining are vertical kiln and rotary kiln. The vertical kiln is suitable for the plants with small production scale. The rotary kiln is used for the plants with large or medium production scale.
The vertical kiln is the kiln whose cylinder is stand on end and can not be rotary. The vertical kiln can be classified into common kiln and mechanized kiln. The common kiln is using artificial materials Feeding and artificial materials discharging or mechanical materials Feeding and artificial materials discharging. The mechanized kiln is using mechanical materials Feeding and mechanical materials discharging. The mechanized kiln is working continuously. Its production quality and productivity are quite higher than common kiln. In recent years, most of foreign vertical kilns are replaced by rotary kiln. In our country, the vertical kiln plays an important role in the current cement industry. Accorrock to the builrock materials technology policy requirements, small cement plants uses mechanized kiln to replace the common vertical kiln.
Kiln cylinder is put in horizontal way( with a certain of inclination, 3% or so) and can do gyratory motion. The rotary kiln can be classified into two kinds: the dry kiln in roasting raw materials powder, the wet kiln in roasting materials pulp(water content is 35% or so).Next:
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