First, the design of the production process and the selection of process equipment should meet the following requirements:
1 should be determined comprehensively according to production methods, production scale, product variety, original, fuel performance and construction conditions;
2 should choose to produce reliable, energy-saving and environmentally friendly process technology and equipment;
3 New technologies, new processes and new equipment that are conducive to improving the comprehensive utilization of resources and co-processing wastes should be adopted;
4 Under the quality requirements of finished and semi-finished products, the process links should be reduced and the material transportation distance should be shortened;
5 The selection of auxiliary machines should have reserves. Under the premise of ensuring production, the number of auxiliary machines should be reduced, and the models of similar auxiliary machines should be uniform;
6 Wear-resistant process equipment, non-standard parts, valves and ducts should be wear-resistant.
Second, the process layout should meet the following requirements:
1 The general layout should meet the requirements of the process, and should be combined with the conditions of terrain, geology and transportation;
2 The process layout should have reasonable development space;
3 The layout of the workshop should be comprehensively determined according to the process flow and equipment selection, and should meet the requirements of construction, installation, operation, maintenance, inspection and passage in the plane and space arrangement;
4 Equipment arranged in the open air shall meet the requirements of production operation, maintenance and repair, and safety protection.
Third, the material balance calculation should meet the following requirements:
1 The material balance calculation of the complete cement production line and clinker production line shall be based on the clinker production of the firing system, and the material balance calculation of the cement grinding station shall be based on the cement production;
2 In the material balance calculation of the complete cement production line and clinker production line, the consumption quota of various materials should meet the following requirements:
1) The dry consumption quota of each raw material shall be determined by the raw material consumption quota and ratio;
2) The consumption quota of raw meal should be composed of the theoretical consumption of raw meal and production loss;
3) The dry consumption quota of gypsum and mixed materials shall be calculated according to the blending amount in the cement and shall be included in the production loss;
4) The fuel consumption quota shall be calculated separately for the coal for firing and the coal for drying.
3 The dry material consumption quota should be converted into the wet material consumption quota according to the moisture of each material, and then the hourly, daily and annual dry and wet material requirements should be calculated.
4 In the calculation of the production loss of the complete cement production line and clinker production line, the production loss of coal should be calculated at 2.0%, and the production loss of other materials should be calculated at 0.5%. The production loss of all materials in the cement grinding station shall be calculated at 0.5%.
Fourth, the annual design utilization rate of major process equipment should be determined according to the size of the plant, the complexity of the production system, the type of host, the source of the equipment, the conditions of use, etc., and meet the requirements of the following table:
|Serial number||Main process equipment name||Annual utilization rate（%）|
|2||Raw material mill||70~80|
|6||Cement packaging machine||>20|
Fifth, the main production system work system should be determined according to the relationship between the systems and the conditions associated with external conditions, and meet the following requirements:
|Serial number||Main production system name||Working days per week（d）||Daily work shift|
|2||Limestone pre-homogenization (stacking)||5~7||1~2|
|3||Limestone pre-homogenization (recovery)||7||3|
|4||Raw material grinding||7||3|
|5||Raw material homogenization and kiln||7||3|
|6||Pulverized coal preparation||7||3|
|8||Clinker storage and transportation||7||3|
|11||Cement packaging and bulk||5~7||1~3|
|12||Coal, gypsum, silicon-aluminum raw materials broken||5~7||1~2|
|13||Compressed air station||7||3|
Note: The work shift system is based on 8 hours per shift.
In the case of non-cooperative disposal of waste and no bypass and venting, the energy efficiency design index of the clinker firing system of various scale production lines of precalcining kiln shall comply with the current national standard “Cement Factory Energy Conservation Design Specification” GB 50443 Provisions.
Sixth, the performance evaluation of the host should be carried out under the design conditions of raw materials, fuel composition and performance. The performance requirements of the host should meet the following requirements:
|Production system||Checking time||Examination content|
|Raw material grinding system||2*18h||Average hourly output, raw meal fineness, moisture, power consumption per unit of product|
|Cement grinding system||2*18h||Average hourly production, cement specific surface area, pass rate, system product power consumption|
|Firing system||72h||Average daily production, clinker burning heat consumption, clinker quality (free calcium content, 3d and 28d strength), cooling machine clinker temperature, unit product power consumption|
Seventh, the maintenance facilities of the production workshop shall meet the following requirements:
1 The inspection equipment of the main equipment shall meet the following requirements:
1) When the components to be repaired are large in the crusher, the transmission device of the grinding equipment, and the series mill with the factory building, lifting equipment such as bridge cranes and suspended cranes should be installed;
2) Above the equipment such as large fan, classifier, car press and other equipment with factory building, electric hoist, single beam crane or other types of lifting equipment should be installed;
3) The hoist should be set up on the head of the hoist.
2 The lifting capacity of the lifting equipment shall be determined according to the weight of the assembly that is the heaviest lifting or the lifting of the assembly.
3 The height of the rail top of the crane and the height of other lifting facilities shall meet the requirements for the maximum lifting height of the lifting object.
4 The design and equipment layout of the plant shall not affect the operation of the lifting and lifting facilities and the lifting of the objects.
5 The maintenance platform or the transportation space required for the installation and maintenance of the space, the door opening and the equipment transportation and maintenance shall be set according to the installation and maintenance requirements of different equipment.
Eighth, the material transport design should meet the following requirements:
1 The selection of material conveying equipment should be determined according to the nature of the conveying materials, conveying capacity, conveying distance, conveying height, etc.
2 The conveying capacity of the conveying equipment should be higher than the actual maximum conveying capacity, and the excess capacity of the conveying capacity should be determined according to the fluctuation of different conveying equipment and incoming materials;
3 The transfer point of the conveying equipment should be set according to the nature of the conveying material. The cutting slip should reduce the drop, and the material of the granular material should have anti-wearing and noise reduction measures.
Ninth, the process design of special areas should meet the following requirements:
1 In the construction of high-altitude areas, the selection of equipment such as rotary kiln, preheater, burner, drying mill, dryer, cooler, fan and air compressor should be corrected according to altitude;
2 The motor should meet the requirements of high altitude when ordering;
3 It is advisable to expand the thermal insulation range in the construction of cold areas, and take anti-freezing measures to ensure the smooth flow of gas, oil and water in production.