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ROTARY KILN CEMENT PLANTS
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Rohrex supplies and installs a specialist range of small
and medium capacity cement plants worldwide.
Our design and
engineering team will provide innovation, high quality
and cost effective solutions for all your project
requirements.
We offer VSK cement plants from 100 TPD to 300 TPD
and ROTARY KILN plants from 400 TPD to 1500 TPD
capacity on a turnkey basis. We will provide assistance
on all aspects of the project cycle including feasibility
and technical studies, plant and equipment design
and specification, construction supervision, trial
runs and commissioning.
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Environmental
and pollution controls
Our emissions
and environmental controls are to the highest
European standards . We also have specialist
expertise in the latest standards required
by all the accession countries to the EU.
Highly
efficient measures for dust and pollution
control are incorporated at every material
transfer point.
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| Features |
- Low
pressure drop pre heaters.
- Raw
mills equipped with High efficiency
separator.
- Raw
Meal blending in CFC silos.
- Expertise in alternative fuels including
biomass.
- Inlet
& discharge fitted with special
seals.
- Pre-calciner
suitable for alternative fuels.
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| Benefits |
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Low
Maintenance.
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Easy
Plant Operation.
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Efficient
power usage.
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Fuel
efficient .
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Low
Installed cost.
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Proven Technology.
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| Cement Manufacture |
1. Crushing &
Proportioning:
Primary
crushing involves limestone rock
fed through large capacity crushers.
This reduces the rock to a maximum
size of approximately 150 mm.
Secondary crushing further reduces
this to 75mm or under. Residule
material is stacked and reclaimed
with a bridge reclaimer in a cross
section so that the homogeneous
limestone is fed further in the
process. This averages the limestone
quality.
2. Raw milling & Blending:
Crushed particles are ground to
90 microns or less in a closed
circuit ball mill with high efficiency
separator. The raw meal is transferred
to continuous blending silos (CFC)
for homogenization ,extracted
by load cell hopper for feeding
to the kiln pre heaters.
3. Pyro
processing:
Raw material is heated to over
1,450 °C in a pre-heater tower,then
through a pre-calciner and finally
to the rotary kiln.
4. Burning :
As the material progresses through
the kiln, certain elements are
removed in the form of gases.
The remaining elements unite to
form a new substance (clinker)
with new physical and chemical
characteristics. Clinker is formed
in small marble sized pieces.
5.
Cooling:
Clinker is discharged from the
kiln and the temperature is reduced
in grate coolers. The hot air
from the coolers is redirected
back to the kiln, this saves fuel
and increases burning efficiency.
6 .
Milling, Storage & Packing:
Portland cement, the basic ingredient
of concrete, is a combination
of calcium, silicon, aluminum,
iron and small amounts of other
ingredients to which gypsum is
added in the final grinding process
to regulate the setting time of
the concrete.
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Rotary Kiln Cement Plant Project
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| Plants Offered |
400 |
600 |
900 |
1200 |
1500 |
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| Land area required
(Sq. M) |
40,000 |
80,000 |
100,000 |
125,000 |
175,000 |
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| Captive Power Requirements
(KW) |
4000 |
6000 |
8500 |
10,000 |
12,500 |
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| Project Lead time (months) |
15 - 18 |
16 - 18 |
16 - 18 |
16-16 |
22-26 |
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| Raw Material
Requirements (Tons Per Day) |
| Lime Stone |
600 |
900 |
1,350 |
1,800 |
2,250 |
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| Clay |
60 |
90 |
135 |
180 |
225 |
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| Coal (4500 kcal/kg) |
60 |
120 |
180 |
240 |
300 |
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| Gypsum (approx. 5%) |
15 |
30 |
45 |
60 |
75 |
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| Manpower (for
3 shift) |
| Administrative &
Managerial |
4 |
4 |
4 |
6 |
8 |
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| Technical & Laboratory |
6 |
6 |
10 |
12 |
14 |
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| Skilled Workers |
10 |
10 |
12 |
15 |
18 |
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| Unskilled Workers |
20 |
20 |
24 |
30 |
36 |
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| Utilities |
| Power (KWH/T) |
100 - 110 |
100 - 110 |
100 - 110 |
90 - 100 |
80 - 90 |
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| Fuel (kcal/kg) |
850 - 900 |
850 - 950 |
800 - 850 |
750 - 800 |
750 - 800 |
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