1500tpd Cement Grinding Station

• Customization: Available
• After-sales Service: One Year
• Warranty: One Year
• Model NO.: 1500tpd
• Bucket Elevator: Hl630X25000
• Electro-Vibrating Feeder: Dz4
• Bag Filter: Ppc32-4
• Transport Package: Case
• Specification: 6000x12000x6000mm
• Trademark: jinrong
• Origin: China
• Package Size: 600.00cm * 1200.00cm * 600.00cm
• Package Gross Weight: 30000.000kg

Product Description

1. Production scale, production method and cement types1.1Production method

Φ3.5*13m
The production method is close circuit process. A ball mill(Φ3.5*13m) cement grinding station with separator will be adopted
1.2Production scale and capacity
62.5t,1500t, 450000.
The production capacity is 62.5t/h for cement, while 1500t/d, 450000t/for one year.
2.Main technical characteristics
2.1
This production line adopts advanced technology and equipment of current cement industry. With the advanced technology and dependable equipment, great economy benefits may be acquired. New model dust collector made in China according to import technology from FK Company, can improve the technology greatly.
2.2,According to requirements of close circuit process technology, design concept in electric and automation control is to use advanced, practical and reliable control method in main production sections, and to use practical and reliable control method in other production sections. The control should be practical, reliable and reasonable in the mass.
2.3
Great importance has been attached to the environment protection in the plan. In order to measure up to the environment protection standard, advanced and practicable dust collectors are adopted at all dust points.
3. Factory construction conditions (climate, etc.)
4.Technical plan
4.1Layout and transport
4.2 Raw materials and material blending
4.2.1 :raw material
4.2.2 Balance of materials    
,62.5T,82% (300day/year)
Calculation of materials balance is made according to the following parameters: cement ball mill capacity: 62.5t/h, annual running ratio: 82%,.
Material balance list 

No.	Name	Ratio %	%moisture	Rating consumption(t/t cement)		Material balance (t)
						Dried			Wet
				Dried	Wet	Hourly	Daily	Annually	Hourly	Daily	Annually
1	Clinker	80		50	50	50	1200	360000	50	1200	360000
2	Gypsum	5	8	3.125	3.4	3.125	75	22500	3.4	82	24600
3	Additive	15	2	9.375	9.6	9.375	225	67500	9.6	230	69000
4	cement					62.5	1500	450000

 5,Production technologic project
5.1  Selection of cement grinding system
,Ф3.5*13m,≤25mm.320m²/kg62.5t/h.
Ф3.5*13m closed-circuit cement mill is adopted. Size input into cement mill: ≤25mm. Average fineness of cement Blaine, 320m²/kg,production capacity is 62.5t/h.
5.2 Selection of cement packing system

6,Brief introduction of process flow
6.1clinker storage

 be fed into the different silo by bucket elevator .
6.2clinker storage
be fed into the different silo by bucket elevator .
6.3 Raw material blending
3,. ,,,.
Five materials blending bins for clinker Speed governable belt balances will be used at the bottom of the material blending bins. Raw materials will be blended according to requirements and fed onto the raw mill by belt conveyor. 
6.4 Cement grinding
,φ3.5*13m,TS-4,,.
After material blending at bottom of clinker silo, admixture silo and gypsum silo, material will be fed into the cement mill (size: Φ3.5*13m). Then material will be fed into separator by bucket elevator.  Finished product will be conveyed into three cement silos via elevator. Coarse powder will return to mill to regrind.
6.5Cement storage and Cement packing
3-Φ6×15m,500,1.
8,100t/h.,,8,.
,.
Three round silos (size: 3-Φ6×15m; Storage capacity: 2000t, storage period: 1days) will be used for cement storage.
Feeding cement from cement silo to packing machine,An 8-spout packer will be used for cement packing. The packing capacity is 100t/h. Cement will be fed into vibration sieve by elevaator, then into cement hooper, and then into 8-spout packer. Bagged cement will be sent into loading machine by belt conveyor.
The weight of each bag will be measured and adjusted by electron balance when packing.
Packing system sets well soot-eliminating devices to ensure the exhaust standard.
7, Design basis
7.1,,;
In accordance with related data supplied by process, civil engineering and water supply & drainage specialties
,.
Following principle of practical, reliable, economic and reasonable design with advanced technology
7.2Power supply and distribution
7.3 Power source
1500t/d11kV ,11kV,.50Hz.,.
The power supply source for 700t/d cement grinding line adopts 11kV single circuit power supply. Frequency: 50Hz. In order to ensure lubrication system not be damaged in case of power cut because of main power source in fault sate.
7.4Voltage
: 11kV ;11kV   
Received power voltage: 11kV            
:11kV 380V/220V  
Distribution power voltage: 11kV 380V/220V
:11kV
High-voltage motor power voltage: 11kV          
:380V, DC440V
Low-voltage motor power voltage: 380V, DC440V
:380V/220V  
Control power voltage: 380V/220V         
:220V
    Operating power voltage in transformer station: DC 220V
:380V/220V ,+PE
Illumination power voltage: 380V/220V,3-phase 4-line+PE
PLC:24V
PLC Control power voltage: DC 24V
    :24V
    Testing components power voltage: DC 24V
7.5 Reactive power compensation
:,400V,11kV,0.92.    Reactive power compensation method: winding motor adopts static phase-adding compensation by the side of the machine, the low- voltage capacity compensation is set by the 400V side of each transformer substation, static capacity compensation is set by the 11kV side of general substation, the power factor should be above 0.92 after compensation.
8, 
Power system
8.1General substation for the whole plant
11kV 1000KVA, 11kV,1000KVA,11kV,.,,,,.
Set a new 11kV,1000KVA main transformer.Adopt 11kV power distribution system to supply power to workshop transformer substation and high-voltage motor. A transformer is set in transformer substation for cement grinding station. It supplies power to low-voltage equipment, including clinker silos, cement grinding workshop, cement silos, cement packing workshop, measuring station and illuminatio in factory area.
,11kV,11kV,,11kV,11kV.
General substation adopts indoor arrangement; the building is of double-layer structures; sets  11 kV power distribution room, 11 kV capacitor room and control room etc.
11kV,,,,.
The 11kV relay protection of general substation adopts computer comprehensive automation protection; the protecting device shall have protection, measure, monitoring and alarming functions.
:;;;;;.
The main transformer sets protections as follows: differential protection; zero order over-current protection; timing over-current limit protection; over-load protection; gas protection; temperature protection.
11kV:;;.
The 11 kV reactive circuit sets protections as follows: quick break protection; timing over-current limit protection; grounding protection.
:;;;().   The transformer reactive circuit sets protections as follows: quick break protection; timing over-current limit protection; gas protection; temperature protection (alarming or breaking)
8.2electric equipment model selection
11kV GIS,11kVXGN,GGD,MCCGCS.,,220VDC.,,,;,,.
11kV high-voltage cabinet is XGN type fixed cabinet. Low-voltage cabinets are all use GGD model cabinets. The high-voltage cabinet is equipped with computer protection device and vacuum breaker with spring operating mechanism. Operating power source is 220VDC. To save investment, all the components in high-voltage cabinets use high-class components made in China, all vacuum breakers use high-class components made in China, all main loop components in low-voltage cabinets use high-class components, accessorial components such as pushbuttons and signal lights use high-class components made in China.
8.3 Electric drive and control for workshops
8.3.1 control form of the motor
DCS,,.,DCS,.MCC"","",""."",DCS,"" ,"""" ,,,."",,.,"","","",,.
The production line adopts DCS control. The central control room is set above the electric room , with computer working station. For equipment control, it shall give control room priority; all controlled equipments can be operated by DCS or manually-operate machine beside equipment with pushbutton box. On each MCC cabinet, there are "remote-control" switches, "on-spot" switches and "maintenance" switches. When the switch is at "remote-control" position, that equipment is controlled by DCS in central control room, while in " on-spot" position, that equipment is controlled by "start" or "stop" button on the pushbutton box beside equipment, which applies in case of test-run or maintenance. While being in " maintenance " position, either "remote-control" switch or "on-spot" switch cannot start the motor, so the equipment is in the state of stop. The "stop" button on the pushbutton box beside machine can stop the equipment that is running, regardless of the switch being in " remote-control " position or "on-spot" position, so as to ensure safety of personnel and equipments that in an emergency.
8.3.2 starting and running form of the motor
75KW;,,;;.:200kW11kV,200kW380V.
The power of low-voltage motors above 75kw are adopted electronic soft starters;high-voltage motors are all started by liquid resistor starters, thereinto, winding motors are used the static phase-advancers to compensate the power factor;Main driving motor of the rotary kiln adopts DC speed control system, other equipment which need adjusting the speed are used AC frequency conversion speed control methods. Motor voltage: motor above 200kW shall adopt high voltage 11kV, motor lower than 200kW shall adopt low voltage 380V mouse cage.
8.3.3 protection form of the motor
11kV,,,,.,.
The 11 kV motor adopts relay protection device to collect voltage and electric current parameter and complete quick break protection, anti-time-limit over current protection, low voltage protection and grounding of protection. The short-circuit protection of low-voltage motor adopts automatic-switch electromagnetism not-fastening device, and over-load protection and lack-phase protection adopt heat relay applicable to motor.8.3.4 the main technical character of the motor
8.3.4.1 11kV11kV medium voltage motor
,11kV,50Hz,S1,F,B,IP44,,,.Pt100.
Manufactured on the basis of China Standard, power votage:11kV, frenquency:50Hz, running form:S1, insulation class: F, temperature: B, protection class: IP44, cooling form: natural wind cooling except that motor for cement grinding machine adapts water cooling. Stator winding of each phase and each bearing is equipped with Pt100 tempratute testing components.
380V 380V low voltage motor
,380V,50Hz,S1,F,B,IP44(IP54),,.
Manufactured on the basis of China standard, power votage:380V, frenquency:50Hz, running form: S1, insulation class: F, temperature: B, protection class: IP44 (IP54 outdoors), cooling form: natural wind cooling
8.4 Wire laying
,YJV,KVV.,.
Laying of cables is as follows: plastic insulation shell cables are used for power cable in workshop, YJV cables are used for high-voltage cable, KVV cables are used for control cable. Power lines are mainly paved in bridges, and partly in channels or tubes.
   :Main technical character of different type of the cables.
8.4.1 high voltage cable
          11 kV rated voltage: 11 kV
                 conductor: copper
            insulation layer: PE
            protection layer: PVC
               3 number of the cores: 3
8.4.2 medium voltage cable
          11 kV rated voltage: 11 kV
         11 kV working voltage: 11 kV
                 conductor: copper
            insulation layer: PE
            protection layer: PVC
               3 number of the cores: 3
8.4.3 low voltage cable
           380V rated voltage: 380V
          380 V AC working voltage: 380 V AC
               conductor: copper
            insulation layer: PVC
            protection layer: PVC
           2.5mm² minimum section area: 2.5mm²
               34 number of the cores: 3 or 4
8.4.4 multi-core low voltage control cable
            380 V rated voltage: 380 V        
 220 VAC 24VDC working voltage: 220 VAC
               conductor: copper
            insulation layer: PVC
            protection layer: PVC
           1.0mm² minimum section area: 1.0mm²
               3-4-5-7-14 number of the cores: 3-4-5-7-14
  8.4.5 multi-core low voltage control shield cable
           380 V rated voltage: 380 V
  24VDC working voltage: 24VDC
               conductor: copper
            insulation layer: PVC
            shield layer: copper netting
            protection layer: PVC
           1.0mm² minimum section area: 1.0mm²
               3-4-5-7 number of the cores: 3-4-5-7
8.6 Illumination
,,,,,.,.
The Seller shall provide the design for illumination indoor and outdoor in the factory. The illumination sources are as follows: incandescent lamp for workshop illumination, fluorescent lamp for transformer substation and control room and high-voltage sodium lamp for road illumination. Emergency lighting shall be considered for control room and transformer substation, and emergency outlet indicator light shall be set in the outlet of each workshop.
     :The illumination standard for each site is as follows:
                250lux central control room: 250lux
        200lux transformer substation and office: 200lux
              100lux production workshop: 100lux
               50lux road for transportation: 50lux
               30lux road for life:  30lux
8.7 Lightning protection and grounding
11kV.
Lightning protection means of lightning rod with grille on the roof is adopted for 11kV general transformer substation.
15,.,, .,,.
If the new workshop is higher than 15m, lightning protection is adopted as building III lightning protection. The balusters of the roof can be used as meeting lightning device, the main reinforcing steel in the pillars can be used as the lead line to the ground, the main reinforcing steel in the reinforced concrete groundwork can be used as grounding poles, as well as, the grounding system of each building need to be connected handy to make of a full lightning protection system of the whole plant.
TN-C-S,.11kV11/0.4kV.11kV,.,,≤4Ω.
TN-C-S Grounding protection will be adopted. The entrances of each building's power source should be grounded repeatedly. 35/11kV main transformer and 11/0.4kV transformer shall adopt neutral position grounding form. Moreover, grounding devices are set separately for 11kV high voltage motors. The lightning grounding and protection grounding are use the same grounding system. All grounding devices in the plant are connected with each other to form the grounding net. Grounding resistance≤4Ω.
8.8 Communication
10,.
20 dispatching telephones are set in the plant for continence of communication among control rooms and other important production posts.
8.9 Wire laying
DJYPVR,,,,,.
Automation control lines adopt fiber or DJYPVR signal cable, they mainly paved in bridges, and partly in steel tubes. If part of the automation control line is identical in directions with electric line, they can share bridges with each other, but with a separating board.
8.10 Automation protection and grounding
,.,,..≤4Ω.
Acousto-optic alarming will be set for part of important parameters to remind the worker of treatment. For parameters related to security, the means of automatically cut-off running of partial equipment and alarming are adopted to assure production safety. The grounding of automation system is included into the grounding system of the whole plant. Earth resistance≤4Ω.
9. Water supply and Drainage
9.
Water demand of the whole plant:150m³/d  
Including: Circulation water demand: 200m³/d 
         Consumed water demand: 50m³/d
         Fire fighting water demand: 54m³ per time
Actual water demand of the whole plant is 50m³/d.
9.2Water supply system
9.2.1
Water source: Water supply available in the plant area is    m³/h that is enough for water demand. 
9.2.2 
Water supply system in plant: Water supply system is used for production, fire fighting, and living. To save water, production-cooling water is circle used. Two cold water pumps (one is reserved) and two hot water pumps (one is reserved) are adopted. The data of cold water pumps is as follows: IS100-80-160A type ,Q=58~90~112m³/h,H=27~24~22m,P=11kW and that for hot water pumps: IS100-65-200 type,Q=65~100~125m³/h,H=55~50~45m,P=22kW. In addition, two cooling towers 100m³ ultra bass counter flow type), two filters (double flow mechanical type), a 100m³ grounding cold pool and a 100m³ grounding hot pool will be adopted.
9.2.3
After finishing of construction of the plant, water drainage amount is not large and it is mainly lab sewage and living sewage, both sewages are without poisonous matters and can be directly drained.
9.2.4Fire fighting

Fire fighting water in the plant is 15 L/ s, a fire lasts 1 hours, water consumption of each fire is 54 m³. When the fire occurs, temporary pressure-adding means will be taken. At original times, two BJ20 type fire fighting pumps will be used.
10. Architecture and structure
10.1 Design principle
The design is based on Chinese current specifications and regulations, The design chooses security, economic and reasonable plan to reach the requirements of process conditions and utilization demands.
10.2 Design of buildings
10.2.1
Roof: Non-temperature-insulation waterproof roof is adopted as ordinary building roof. Natural water drainage is adopted as ordinary building roof water drainage.
10.2.2
Wall: Thickness 220mm
Generally, cement mortar is used to paint outer wall and mixed mortar is used to paint interior wall, and lime slurry is used for whitewashing.  
10.2.3 
Floor: Cement mortar is used for floors of ordinary workshops and assistant building.
10.2.4 
Windows: Concrete blind window, steel and wood door are used for ordinary workshops.
10.2.
Stairs and railings: Use Chinese 87J432 standard drawings.
10.3 Selection of structure style
10.3.1
Main production workshops adopt framework, storage silos larger than 6m in diameter use cast-in-place reinforced concrete structure, storage silos≤ 6m in diameter use masonry and concrete grid structure.
10.3.2
Auxiliary workshop, substations and other buildings use masonry structure
10.3.3 .
Buildings and Structures connection generally use connecting corridor or bridge.
10.3.4 .
Equipment foundation and pit adopt the cast-in-place concrete structure.
10.4
10.4.1
The plant regional topography is of upper pool formed by erosion of karst and the lower rock (average elevation: 5.0m). 
For some special structure and large-scale structures (such as preheater framework and cement silo), mechanical bored piles shall be done, other foundation design uses independent foundation, bar foundation below wall or entire slab foundation.
10.4.2 Natural conditions
Basic wind pressure: Wo=1.25KN/m²
Earthquake-resistance and crack-resistance: degree seven.
Designed basic earthquake acceleration value: 0.10g
Designed earthquake grouping: grouping I
10.5Building materials
10.5.1Concrete:C40,C35,C30,C25,C20,C15.
Designed axis pressure resistance strength and axis pulling resistance strength of concrete are fc and ft respectively, whose values see table 1.1.1

Kinds of strength	Strength grade of concrete
	C15	C20	C25	C30	C35	C40
fc	7.2	9.6	11.9	14.3	16.7	19.1
ft	0.91	1.10	1.27	1.43	1.57	1.71

10.5.2
Reinforced steel: grade I: HPB235; grade II: HRB335; grade III: HRB400
Designed pulling resistance strength and pressure resistance strength of ordinary reinforced steel are fy and  respectively, whose values see table 2.1.1
10.5.3,:.
Brick and stone: selected in accordance with Standard
10.5.4Steel
10.5.4.1
Steel adopted in steel structure are use Q235 grade B carbonaceous steel and low-alloy high-strength steel. Their qualities should be in accordance with recent Chinese national standard "Carbonaceous Steel" (GB700)and "Low-alloy High-strength Steel" (GB/T1591).
10.5.4.2.
Ratio of strength to yield value of earthquake resistance steel should be no less than 1.2; should have obvious yield step; tensibility ratio should be larger than 20 percent; should have good weld ability
10.5.4.3.
Quality of welding rod for manually welding should be in accordance with recent Chinese national standard "Carbonaceous Steel Welding Rod" (Gb5117)and  "Low-alloy Steel Welding Rod" (GB5118). Moreover, welding rod selected should match with body metal.
Welding wire and welding solder for automatically or semi- automatically welding should match with body metal. Welding wire should be in accordance with recent Chinese national standard "Steel Wire for Melt Welding" (GB/T14957) and "Steel Wire for Gas Protection Welding" (GB/T14958).
10.5.4.4.
Ordinary bolts should be in accordance with recent Chinese national standard "Six-angle Bolt---Grade A and B " (GB5782)and "Six-angle Bolt---Grade C "  (GB5780).
Anchored bolts should be Q235 steel or Q345 steel in accordance with recent Chinese national standard "Carbonaceous Steel" (GB 700)and "Low-alloy High-strength Steel" (GB/T1591)..
High-strength bolts should be in accordance with recent Chinese national standard "High-strength Big Six-angle Bolt, Big Six-angle Bolt Nut and Gasket use for Steel Structure and Technical Conditions" (GB/T1228~1231)or "Torsion-shearing High-strength Bolt Joining use for Steel Structure" (GB3632~GB3633).

11,Environment protection
11.1
In accordance with China Standard ,Dust discharge concentration is no more than 50mg/Nm3.
11.2 Dust treatment
Dust is the main pollution of the production line. Dust is from grinding, blending, crushing and transporting, etc. Besides, dust is generated in loading and unloading of all material.
Dust treatment measures are taken as follows:
11.3 
High efficiency bag filters are used to collect dust from production equipment such as ball mill and crusher before discharging into the air of dust.
11.4
By taking means of decreasing fall, sealing production and air draft and purifying, etc, dust generated in transporting, feeding and discharging can be prevent from escaping.
11.5 Wastewater
Wastewater is mainly cooling water for equipment and washing water in workshop, and it has no poisonous matter. In the design, circulation water is adopted. Wastewater discharge is about 10%. Beside production loss, all the other wastewater is circle utilized, and circulation utilization rate is more than 85%.  
11.6Noise
There are several noise sources. In workshop, noise is mainly generated from machine running, and out of workshop, noise is mainly generated from varies of transportation vehicle.
Generally, noise from machine in workshop is at the range of 70~90dB(A), few (such as mill, crusher, blower, etc.) is over 100 dB(A). The following noise protection methods are adopted:
11.7 
Mufflers are adopted at both inlets and outlets of Roots blower.
11.8.
Noise preventing operation room is set at high noise generating workshop.
11.9,.
By planting trees and bushes at spare area can absorb some noise.