How to Make Your Rotary Kiln Cement Plant More Profitable?

A rotary kiln cement plant refers to a cement manufacturing plant with a cement rotary kiln as the main clinker calcination equipment, which can be divided into dry and wet processes. It features high output, environmental friendliness, high-quality 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 can the profits of the rotary kiln cement plant be further improved? 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, set up the clinker production line near the mine and the cement grinding station near the market. Because the most commonly used raw material of a 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 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 gives 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. A 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.

The vertical structure design of the cement vertical mill gives it 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 the cement vertical mill is large. So manufacturers can cancel the secondary crushing according to their needs to reduce equipment investment. Besides, the cement vertical mill has lower infrastructure investment and less noise. This reflects its humanized and modern design.

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.

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 automatic, efficient, high-quality, and low-consumption clinker manufacturing. Besides, it has 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 the 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.

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 systems, closed-circuit grinding systems, pre-grinding systems, combined grinding systems, finish grinding systems, vertical mill grinding systems, 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 for different cement varieties, 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.

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 manufactured. With the continuous progress of technology and processing capacity, the roller press has changed the impression of unreliability and a large amount of maintenance, gradually becoming 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 in the above aspects, we can further improve the cement plant’s profits.