Cement grinding unit is a key link in cement plant. To achieve energy saving and consumption reduction in the cement industry, we must proceed from the cement grinding unit. Through a series of research and analysis, the following seven methods can effectively reduce the energy consumption of cement grinding plant.

1. Improve raw materials and products, and mix materials

Make full use of various industrial waste slags, such as blast furnace slag, steel slag, fly ash, and burned coal gangue. These waste slags are treated at high temperature and help to improve the performance of cement. At the same time, it also reduces the particle size of the grinding material, which can reduce the power consumption per unit product.

2. Effectively control the reasonable particle composition of cement

Under the fixed process conditions, when the 45μm sieve residue and specific surface area of cement are controlled at a reasonable level, particles below 3μm and above 45μm can be limited, so as to obtain good cement performance and lower production costs. Compared with other methods, this fineness control method has the advantages of simple operation and effective control. As long as a sample is taken for a sieve analysis test and specific surface area determination, it can provide a basis for the operation of the cement mill.

3. Reasonable use of grinding aids

In the cement grinding process, a small amount of admixture is added to eliminate the adhesion and aggregation of the fine powder, accelerate the grinding speed of the material, improve the grinding efficiency, and also increase the content of 3-30μm by 10-20%, which is conducive to the high-quality, energy-saving and high-yield of cement ball mill. Such additives are collectively referred to as “grinding aids”. In most cases, the use of grinding aids can increase the output of the cement ball mill without changing the cement production process, the purpose of improving the quality of cement production line, reducing costs, and producing green high-performance environmentally friendly cement can be achieved.

4. Adopt suitable grinding process and energy-saving cement grinding machine

In the cement production process, the use of new technologies and processes can greatly reduce energy consumption, save investment, and achieve economic benefits. Such as multi-point feeding, multi-point retrieving, circulating grinding process; extruder combined grinding process, etc. At the same time, we must vigorously promote to use energy-saving cement grinding equipment. For example, instead of traditional cement ball mills, select new type cement vertical mills, trapezoidal mills, and other energy-saving cement grinding equipment.

5. Optimize the internal structure of the cement mill and set up an efficient forced screening system with powder selection function

At present, these two measures are the main reform directions for the cement mill optimization. The following effects can be achieved: the output is increased by 30% -60%, the power consumption is reduced by 25% -40%, and the power consumption per ton of cement is reduced by 8-12kWh. It can effectively increase the strength of cement. Generally speaking, the strength of cement can be increased by more than 5MPa.

6. Using frequency conversion technology

Frequency conversion technology is one of the energy-saving technologies. This technology can help some auxiliary equipment in cement plant to save energy, such as fans, batching metering, and variable-speed equipment. At the same time, it also meets the characteristics of low-speed operation and large starting torque of the cement ball mill and realizes the continuous adjustment of the running speed of the cement ball mill. There is no inrush current when the motor starts, the starting distance is sufficient, and the protection function is perfect. Ensure the quality of process control and save maintenance costs.

7. Improve the power factor and efficiency of electrical equipment and reduce power consumption

The use of low-voltage motor full-phase control technology, it has the advantage of automatically adjusting the output power of the motor when the load is lightly loaded and heavily loaded so that the motor can save electricity by 15% at the time. Adopt a green lighting system, through these technical measures, greatly improve the power factor, reduce the reactive power demand, and reduce the loss of active power.

In general, correctly coordinating the relationship between quality, output, and the energy consumption is the basic way for cement grinding to save energy and reduce consumption. Traditional cement mills have low energy utilization rate and do a lot of useless work. The energy-saving technology should be the basic task of transforming the cement grinding process, and all these need to be established on the basis of a certain quality index control. To achieve a reasonable particle ratio of cement materials, it should meet the gradation requirements of performance, and add an appropriate amount of industrial waste residue.

As a professional cement project supplier, Henan ZK Corp provides emissions testing services to help determine if plants need to take emissions-reducing measures. For existing plants, we measure current emissions and make improvement recommendations. For new plants, we utilize the best predictive model in the industry, which calculates with great accuracy what the actual levels will be once the plant is up and operating at full capacity.

If you are interested in setting up the cement plant, any technical questions and investment issues you are welcome to contact with us directly.