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Home » How to Make Your Rotary Kiln Cement Plant More Profitable?

How to Make Your Rotary Kiln Cement Plant More Profitable?

Rotary kiln cement plant refers to the cement manufacturing plant with cement rotary kiln as the main clinker calcination equipment, which can be divided into dry process and wet process. It features high output, environmentally friendly, high quality of cement products, etc. With the development of cement production technology, dry process rotary kiln cement plants have gradually become the first choice for cement enterprises. However, for many cement manufacturers, profit is always their most concerning thing. How to further improve the profits of the rotary kiln cement plant? We can take measures through the following aspects.

Cement Plant Site Selection

Cement manufacturers should stop placing a complete cement production line in one site. Instead of that, setting up the clinker production line near the mine and the cement grinding station near the market. Because the most used raw material of cement plant is limestone. Its transportation volume accounts for half of the total logistics, therefore the clinker production line close to the mine can reduce the transportation cost and the risk of affecting the cement production due to the supply of raw materials. Besides, the site selection of the clinker production line should also consider the convenience of transportation and choose a cheap transportation mode as far as possible, which will enhance the ability of market competition. The construction of a grinding station near the sales market helps to establish a brand image and give customers a sense of safety and reliability.

Raw Material Grinding System Selection

The grinding system in cement plants is mainly used for grinding limestone, clay, and other cement raw materials. Because it occupies a high weight in the cement production line, we should focus on efficiency and energy saving in its selection. Cement vertical mill is a grinding device that integrates fine crushing, drying, grinding, grading, and conveying. Because of its power-saving and simple process, it has become the first choice for large-scale cement plants, which has played a positive role in energy-saving and production cost reduction.

Vertical Mill agico
Cement Vertical Mill

The vertical structure design of the cement vertical mill makes it has a small floor area, light weight, long service life of wearing parts, and low power consumption. On the other hand, the feed material size of cement vertical mill is large. So manufacturers can cancel the secondary crushing according to their needs for reducing equipment investment. Besides, the cement vertical mill has lower infrastructure investment and less noise. This reflects its humanized and modern design.

Model Grinding disc diameter 
(mm) 
Roller diameter 
(mm)
Feeding size 
(mm)
Capacity (t/h) Main motor power 
(kw)
Disc rotation speed 
(r/min)
Weight 
(t)
LM0806 800 600 <30 3-5 75 62 13. 8
LM1311 1300 1100 <40  9-15 200 43  46. 5
LM1512  1500 1250 <40  10-19 280 43 65
LM1714 1700 1400 <42 13-32 400 40 90
LM2215 2250 1560 <50 25-45 800 32 120
LM2820  2800 2000 <65 35-80 960 32 200
LM3424 3450 2400 <70 60-100 1350 30 300
LM4831 4800 3150 <115 95-200 3150 26 760
HRM1411 1400 1185 <35 10-15 225 37. 96 49
HRM1612 1600 1200 <40 12-20 280 36. 16 65
HRM1813 1800 1300 <45 16-28 350 34 78
HRM2115  2100 1500 <50 20-35 400 31.6 87
HRM2215 2250 1570 <60 25-35 500 31 92
HRM2417 2450 1750 <70 28-40 630 29. 5 114
HRM2619 2650 1900 <75 35-55 710 28.1 132
HRM3123 3150 2300 <80 40-80 1120 25 210
HRM3424 3450 2430 <80 52-85 1300 24. 5  310
HRM3626 3600 2650 <80 60-100 1950 24 450
HRM4028 4000 2850 <90 70-115 3100 22. 9 600
HRH4230 4250 3050 <100 85-160 3400 22. 18 680
HRM4531 4500 3150  <110  95-200 3600 21.5 750

Clinker Calcination System Selection

Clinker production is the core of rotary kiln cement plants. In the current market, there are mainly dry process clinker production and wet process clinker production.

suspension preheaters
Cyclone Preheater

The new dry process cement rotary kiln is the most advanced clinker calcination system at present. It takes suspension preheater and pre-calcining technology as the core and adopts computer distributed control, which has the advantages of rapid heat transfer, high thermal efficiency, and low heat consumption. It realizes an automatic, efficient, high quality, and low consumption clinker manufacturing. Besides, it has a strong adaptability to fuels. In the past, we thought that the calorific value of coal should be greater than 22990kJ to meet the requirements of precalciner, but now it only needs 18810kJ, or even lower. This greatly reduces the cost of fuel. Therefore, the adoption of a new dry process clinker calcination system has a direct impact on improving the quality of cement products and increasing the profits of rotary kiln cement plants.

Equipment Model Figure Number Capacity(t/d) Weight(t) Notes
Cyclone preheater with calciner RF5/2000 5 stage LX102A 2000 212 Suitable for Ø 3.6 x 54 m rotary kiln
RF5/3200 5 stage LS970-07S-P01 3200 432 Suitable for Ø 4.3x 64 m rotary kiln
RF5/4000 5 stage SY4 4000 355 Suitable for Ø 3.6 x 64 m rotary kiln

Cement Grinding System Selection

The key point of cement grinding system selection is also energy saving as it accounts for the largest proportion of power consumption in cement plants, about 45%. There are various cement grinding systems available on the market, such as open-circuit grinding system, closed-circuit grinding system, pre-grinding system, combined grinding system, finish grinding system, vertical mill grinding system, etc. The open-circuit grinding system refers to a super fine grinding system. Although its energy consumption and investment are low, it is difficult to adjust the cement variety, and the product temperature is too high. The ordinary closed-circuit grinding system features a simple process and stable running, while its power consumption is high, which does not conform to the concept of energy-saving.

agico suspension preheater
Cyclone Preheater

At present, the cement roller press and cement vertical grinding system have become the first choice for large cement plants. Whether pre-grinding or combined grinding, at least 5kWh is saved per ton of cement manufacturing. With the continuous progress of technology and processing capacity, roller press has changed the impression of unreliability and a large amount of maintenance, gradually become the development trend of cement grinding.

Conclusion

Site selection, raw material grinding system selection, clinker calcination system selection, and cement grinding system selection are important factors affecting the successful operation and profit of rotary kiln cement plants. As long as we prepare in advance and take measures from the above aspects, we can further improve the cement plant profits.

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