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.

ModelGrinding disc diameter 
(mm) 
Roller diameter 
(mm)
Feeding size 
(mm)
Capacity (t/h)Main motor power 
(kw)
Disc rotation speed 
(r/min)
Weight 
(t)
LM0806800600<303-5756213. 8
LM131113001100<40 9-1520043 46. 5
LM1512 15001250<40 10-192804365
LM171417001400<4213-324004090
LM221522501560<5025-4580032120
LM2820 28002000<6535-8096032200
LM342434502400<7060-100135030300
LM483148003150<11595-200315026760
HRM141114001185<3510-1522537. 9649
HRM161216001200<4012-2028036. 1665
HRM181318001300<4516-283503478
HRM2115 21001500<5020-3540031.687
HRM221522501570<6025-355003192
HRM241724501750<7028-4063029. 5114
HRM261926501900<7535-5571028.1132
HRM312331502300<8040-80112025210
HRM342434502430<8052-85130024. 5 310
HRM362636002650<8060-100195024450
HRM402840002850<9070-115310022. 9600
HRH423042503050<10085-160340022. 18680
HRM453145003150 <110 95-200360021.5750

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.

EquipmentModelFigure NumberCapacity(t/d)Weight(t)Notes
Cyclone preheater with calcinerRF5/20005 stageLX102A2000212Suitable for Ø 3.6 x 54 m rotary kiln
RF5/32005 stageLS970-07S-P013200432Suitable for Ø 4.3x 64 m rotary kiln
RF5/40005 stageSY44000355Suitable 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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