45-Minute Walkthrough Inside Modern Cement Grinding Plant Full Process Introduction Portlant PO42.5.

Описание: https://cementl.com/ Today we made a 45 min introduction of a modern cement grinding plant ball mill+roller press system.

Website: https://cementl.com/
Email: [email protected]
Whatsapp: +86 15988878668

1. Roller Press Pre-Grinding System
The roller press is the first key equipment in a closed-circuit cement grinding plant. Acting as a pre-grinder, it uses two counter-rotating rollers that compress the clinker under high pressure. This process cracks the particles and significantly reduces the energy consumption of the subsequent ball mill. Compared to open-circuit systems, the roller press increases output by 30–50% while maintaining uniform particle size distribution. The compressed cake coming out of the roller press is then fed to a V-separator or directly to the ball mill for further grinding. The main advantages include lower specific energy use (as low as 25 kWh per ton), improved particle size control, and reduced wear rate in the mill liners.

2. Ball Mill Grinding System
After pre-grinding, the material enters the ball mill, which performs the main fine grinding stage. The ball mill consists of a rotating cylindrical shell filled with steel balls. As the shell rotates, the grinding media cascade and crush the clinker particles, blending them with gypsum and other components to achieve the desired fineness. Inside a closed-circuit plant, the ball mill is integrated with a high-efficiency dynamic powder separator, forming a circulation system. Oversized particles are returned to the mill, while fine cement powder is carried forward to the next stage. This process ensures consistent fineness, stable performance, and higher production output with reduced energy waste.

3. High-Efficiency Powder Separator
The separator is the brain of the grinding circuit. It classifies the cement powder based on particle size and ensures that only fine, qualified material leaves the system. The latest generation of separators uses rotor-driven airflow and variable-speed control for precise classification. By optimizing the separator’s rotational speed and airflow, the plant can fine-tune cement fineness—from 3200 to 4500 cm²/g Blaine—depending on product grade requirements (such as PO42.5, PO52.5, or composite cement types). A good separator can boost mill output by up to 20% and reduce power consumption by 15%.

5. Dust Collection and Air Control System
Cement grinding generates fine dust, and controlling it is crucial for both efficiency and environmental compliance. A network of pulse jet bag filters and air slide systems maintains clean airflow and recovers valuable product dust. Proper air balancing between the ball mill, separator, and elevator ensures stable pressure, improving material transport and classification accuracy.The filtered air meets strict emission standards (30 mg/Nm³), demonstrating the plant’s commitment to sustainability and workplace safety.

6. Material Conveying and Storage System
After classification, the finished cement powder is pneumatically or mechanically conveyed to storage silos. Air slides, screw conveyors, and bucket elevators transfer the cement gently to avoid particle segregation. Each silo is equipped with fluidizing pads, level sensors, and extraction systems that keep the product homogeneous and flowable.Typically, silos are designed for 5,000–20,000 tons capacity, allowing the plant to store different grades of cement before dispatch.

7. Bulk Loading and Packing System
The final stage of the cement grinding plant is the packing and dispatch section, where cement leaves the factory for customers. The system includes automatic rotary packers capable of filling 25kg or 50kg bags at speeds up to 120 tons per hour. For bulk delivery, a truck loading system transfers cement directly from the silo to tankers via screw conveyors or air slides. The bulking system ensures fast, dust-free loading operations, enhancing logistic efficiency. Advanced weighbridge control and barcode systems also ensure product traceability and accurate loading records.

8. Automation and Control System
Modern cement grinding plants operate under full automation. Distributed Control Systems (DCS) continuously monitor temperature, pressure, vibration, and power consumption at every stage. Operators can visualize real-time data through SCADA interfaces, making precise

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