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PENGFEI – IRD Swiss Project 6000 TPD Clinker
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TECHNICAL REPORT
FOR
6000 TPD CEMENT Clinker Plant
1.8 Mio TPA (Year)
Asset List & Delivery List
PENGFEI – IRD Swiss Project 6000 TPD Clinker
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1
GENERAL
1.1 INTRODUCTION
EGYPT CEMENT COMPANY wish to install one new Greenfield cement
factory using dry process technology with the capacity of 6,000 tons
cement per dayin Egypt. The scope of supply is required on the turn-key
basis, which includes Cement Production Line only. JIANGSU PENGFEI GROUP CO.,LTD and IRD Swiss. (hereinafter called “Contractor ") are invited to prepare the quotation for the Owner. The scope of supply in this quotation covers Cement production line from the raw material crushing to cement packing on the basis of turn-key basis.
The clinker burning system of FL-Smith latest developing technology will be applied to in the quotation. The preheater, calciner, rotary kiln and some other auxiliary equipment are also belong to FLS’s technology and will be manufactured in China. There is also some equipments in which have license agreements with FLS Europe Companies, for example, the EP, bag filter, weighing equipment, etc. The equipment offered is reliable and have been validated in so many cement projects with successful operation in recent years. This offer also include lots of equipment items from a third country, such as grate cooler, Coal power weighing , DCS control system etc.
The experienced workers from Contractor will execute or supervise all
works of equipment erection for 6,000 tpd clinker production line; civil
construction and it will be helpful for project quality control and schedule
control. 1.2 SCOPE OF WORK 1.2.1 Machinery supply 1.2.1.1 The scope of Machinery supply of this proposal for Egypt Cement
Project is from the raw material crushing to the cement packing and
dispatching for cement production line, which are divided into the
following systems:
Department 1: Preparation of raw materials
Section 1: Limestone/shale Crushing &
Conveying Section 2: Limestone/shale Preblending Storage & Conveying Section 3: Gypsum/additive Crushing& Conveying Section 4: Gypsum/additive Preblending Storage& Conveying
Department 2: Raw Meal Preparation Section 1: Raw Material Proportioning Station Section 2: Raw Material Grinding
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Section 3: Exhaust-gas Handling Section 4: Raw Meal Homogenizing Silo & Kiln feeding System
Department3: Clinker
manufacture Section 1:
Preheater & Precalciner
Section 2: Kiln & Tertiary Air
Duct
Section 3: Grate Cooler Section 4: Kiln Ignition Pump System Section 4: Clinker Storage & Conveying
Department 4: Cement manufacture Section 1: Cement Proportioning Station Section 2: Clinker Grinding System Section 3: Cement Storing & Bulk Loading
Department 5: Cement Packing Section 1: Cement Packing Section 2: Cement Big Bag Loading
Department 6: Coal Handling System Section 1: Raw Coal Preblending Section 2: Coal Grinding System
Department 7: Power and control network Section 1: Main substation Section 2: Electrical rooms Section 3: Control network
Department 8: Quality control Section 2: CCR Section 3: LAB
Department 9: Water treatment Section 1: Water treatment Section 2: Drainage and Sewage
Department 10: General Plant Service Section 1: Compressed Air Station Section 2: Weigh Bridge(s) Section 3: Mechanical and Electrical Workshop Section 4: Gasoline station Section 5: Garage Section 6: Brick (refractory) storage
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Non-Production Buildings & Structures (Except any equipment & furniture)
Fire fighting system Administration building Sales office Gate house(s) Canteen Clinic Sanitary Blocks
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1.2.1.2 The following auxiliary equipment and other equipment in EgyptCement Project will be included:
Belt conveyor Bucket Elevator Air slide Screw conveyor Chain conveyor Apron onveyor Apron feeder Rotary feeder Dust collector Ventilator and fan Damper & lve
Metal detector Magnetic oparator Dosing and weighing equipment Weighing bridge Grinding media Refractory Insulation Sampling equipment Laboratory equipment
Electrical Equipment Motor
control centers Field instrumentation DCS system Wire and Cable Plant Lighting Water Supplying and Drainage Emergency power generator Non-standard Parts Two-Year Spare Parts
1.2.1.3 The sources of machinery supply will be indicated in following designations:
SS – Contractor supply TS – Third country outside China supply (Contractor’s Responsibility).
1.2.2 Engineering
a) Basic engineering: design and supply of basic engineering of EgyptCement Project.
b) Detailed engineering: Design and Supply of detailed drawings for the civil
works and equipment installation and site fabrication. The operation and
maintenance instruction, specification and other information necessary is
also included.
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1.2.3 Erection and Commissioning
The scope of equipment erection includes mechanical erection, Installation
of electrical, instrumentation and control systems for Egypt Cement Project.
The tools and other facilities required for the equipment erection are
included.
Commissioning and performance test are also in the scope of supply for
Egypt Cement Project. Commissioning of the project will be carried out by Contractor’s personnel and the Owner's personnel, adequately trained by Pengfei.
1.2.4 Training
The Owner's engineering and operation staff will be provided with suitable
training services. The objective of this training is to provide the Owner's
personnel with sufficient knowledge and skill on the works of respective
categories which will be required for the operation, maintenance and control
of the cement plant.
The training will be sub-divided into two
categories: a) Overseas training
JSPF will train the Owner's personnel in the JSPF's office and at existing
cement plant(s) of similar design/size.
b) On Site Training
JSPF will provide the Owner's personnel with on-site training, which shall be
carried out before and during the No-Load Test/Load testing and
commissioning period. This training will be carried out by the IRD Swiss
supervisors and commissioning engineers.
The duration of the training, the number of personnel to be trained overseas
and other detail information is described in Engineering Execution Volume of
our quotation. 1.2.5 Civil Works
The civil work consists of the execution and completion of the civil and steel
structural works together with related services of above described
departments in Egypt Cement Project.
The Contractor will be responsible for provision of camp and other temporary
and permanent installations at site necessary for the execution of the works.
In these project Civil Works is not included in the scope of Contractor. 1.2.6 The scope of equipment supply includes ocean freight, freight insurance and
inland transportation to site.
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1.2.7 Exclusion
The exclusion of the machinery supplies for Egypt Cement Project in the offer is as following:
Limestone quarry
Roads to the plant and other facilities outside the plant
Custom duty for equipment imported to Egypt if it has to pay
Civil Works
1.3 STANDARD AND CODES 1.3.1 Engineer Design (Electrical, mechanical & Civil) criteria –ISO Standard 1.3.2 Equipment (Electrical & mechanical) design & manufacturing standard--
Chinese Standard & ISO & standards for the equipments from the 3rd country.
1.3.3 Erection and installation standard-- ISO Standard &The standards for the
equipments from the 3rd country. 1.3.4 Maintenance and safety aspect–ISO Standard 1.3.5 Civil Design criteria –ISO Standard
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2 PROJECT CONDITIONS 2.1 SITE TOPOGRAPHY
The site topography is not received. The final design elevation will be
accordant with the topography which shall be offered by the Owner. 2.2 SITE LOCATION
The site location for the 6,000tpd Clinker Production Line will be located in Egypt.
2.3 RAW MATERIALS AND FUELS 2.5.1 Chemical composition of raw materials
The chemical composition of the raw materials is offered by the Owner , but
now we cannot received it
2.5.2 Fuel
The fuel would be bituminous coal for the project.
The fuel’s specification is offered by the Owner, the owner shall send the coal
samples to JSPF.
2.4 Water Supply
Water demand for the project shall be met from ground water sources.
The design capacity of water sources and water treatment is exclude the part
of power plant.
The quote of this source water is according to three deep wells (Φ300mm),
the depth of each well is not more than 200 m .
Hardness of source water is not more than 600mg/L(according to CaCO3 ),
the other indicators of water quality should be in line with "Water Quality
Standard for Drinking Water Sources"(GB 5749-2006)
2.5 Power supply
No Power supply information
2.6 CLIMATE DATA 2.9.1 Altitude
Site altitude is approximately xxx above mean sea level.
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2.9 2.9.2 Rainfall
Average rainfall (annual): xxxmm
Max. Rainfall (Only one day) xxxmm
2.9.3 Temperature
Annual average: xxx℃
Maximum average: xxx℃
Minimum average: xxx℃
2.9.4 Relative humidity
Maximum average: xx%
Minimum average: xxx%
2.9.5 Wind
Prevailing Wind direction: xxx
Max. wind velocities: xxxm/s
2.9.6 Seismic
xxx.
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3 TECHNICAL SPECIFICATIONS
3.1 PRODUCTION SCALE AND CEMENT TYPES
Production scale: 6,000 t-clinker TPD
Cement types: Ordinary Portland Cement (Type I,II ASTM)
3.2 RAW MATERIALS AND FUELS
3.2.1 Chemical composition of raw materials is not given by the Owner.
3.2.2 Fuel
The fuel would be bituminous coal for the project.
The fuel’s specification is not offered by the Owner, the owner shall send the
coal samples to Pengfei.
3.2.3 Heat consumption of clinker
Heat consumption of clinker:3053kJ/kg (730kcal/kg)
3.2.4 Consumption of fuel
Consumption of fuel:122.12 kg bituminous coal/t clinker
3.2.5 Setting of clinker target value
According to the products of this project and the features of the raw materials
and fuel, referring to the successful experience of the same type kiln and
production process, the clinker value rate is set as follows:
LSF=92.0~96.0
KH=0.89~0.93
SM=2.40~2.70
AM=1.40~1.80
In which:
LSF=100CaO/ (2.8SiO2+1.18Al2O3+0.65Fe2O3)
KH= (CaO-1.65 Al2O3-0.35 Fe2O3)/2.8SiO2
SM= SiO2/ (Al2O3+Fe2O3)
AM= Al2O3/ Fe2O3
3.2.6 Chemical composition of raw meal (%)
L.O.I SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl- Total
32.14 13.70 3.31 2.11 43.12 0.76 0.13 0.06 0.26 0.015 95.61
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3.2.7 Chemical composition of clinker (%)
L.O.I SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Cl- Total
20.97 5.09 3.13 62.33 1.11 0.19 0.12 0.83 0.022 93.7
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3.2.8 Clinker value rate
KH LSF SM AM HM
0.900 93.38 2.55 1.62 2.14
3.2.9 Mineral composition, Liquid and Na2Oeq
Mineral
composition(%) 1400℃ Liquid Na2Oeq
(%) (%)
C3S C2S C3A C4AF
53.24 19.90 8.17 9.53 23.45 0.25
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3.3 GENERAL LAYOUT 3.3.1 Brief introduction
The principles of general layout arrangement are as follows:
The code & standard should be satisfied the requirement for process,
transportation, fireproofing and construction.
The plant layout should be suitable to the site topographic and process
requirement.
The layout is elementary because there is no site topographic map. It would
be adjusted according to the future topographic map.
The project area within the boundary is about 40 ha which exclude the area of
the future production line. 3.3.2 Vertical design
The site topography may be flat. Its natural elevation is not assured now. The
design elevation of the site will be according to the topography. The final
design elevation will be accordant with the topography.
Designing ground will be slope from building to road. 3.3.3 Rainwater drainage
Surface water run-off from the site will be collected with the ditch which will be
designed and constructed out of the roadside. The drainage outlet position for
surface water and drainage is at west or east of the plant. 3.3.4 Transportation
3.3.5 Road design inside the plant
To meet the requirements of production, maintenance, and fire controlling, the
road within the plant is arranged in circle.
Roads will be designed to take account of the traffic frequencies,
configuration, and loading of all vehicles to be used during operation of the
plant. 3.3.5.1 Roads design standard
Roads and surfacing will be designed in accordance with the Chinese
specifications first, then review with local road standard.
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3.3.5.2 Classification of road
According as the traffic loads, frequencies, and conditions of road zone, the
classification of road is applied as follow:
WIDTH(m) STANDARD D.S.(km/h) REMARKS
MAIN 7.0~12.0 20 D.S.
SECONDARY 4.0~6.0 15 =design speed
Sidewalk width is: 1.5~2.0m.
3.3.5.3 Road slop
WIDTH(m) MAX. SLOPE (%) MIN.SLOPE (%) REMARKS
MAIN 7.0~12.0 6.0 0
SECONDARY 4.0~6.0 6.0 0
3.3.5.4 Pavement and base course
Roads and paved areas inside the plant will be designed with cement
concrete and asphalt concrete pavement.
The required cement concrete slab thickness for roads and pavements will be
minimum 200mm.
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3.4 CEMENT PRODUCTION LINE 3.4.1
Brief introduction to process flow
EgyptCement Project is 6000 tpd product line. The system will be described as
following. 3.4.1.1 Limestone/clay crushing & conveying
The limestone/clay crushing workshop will be located in the quarry. There are 2 hoppers in this department. The limestone will be dumped into one hopper, Clay is dumped into the other hopper. They are mixed together according to the proper proportion. There will be an apron feeder under each hoppers, raw material will be fed into a double rotor hammer crusher by the apron feeder. The crusher capacity will be 1300 t/h with a maximum feed size of ≤1200 mm
and a discharge size of 80% ≤100 mm. Then the crushed raw material blending will be sent to the limestone/clay preblending storage via belt conveyors for preblending and storage. A γ-ray analyzer will be provided to control the material proportion.
The over countryside belt conveyor is about 600m long and the speed is about 1.25 m/s..
3.4.1.2 Limestone/shale preblending storage & conveying
One covered longitudinal stockpile will be provided for limestone/clay blending
and raw material proportion. The stockpile will be chevron stacking. One luffing
type stacker with the capacity of 1300t/h is envisaged for the stockpiles.
Laterite will be stacked by the pay-off loader.
The blending stockpile capacity is described as following:
Limestone mix : 2 x 30,000 t
Laterite : 1x 5,000 t
Limestone : 1x 5,000 t
Clay : 1x 5,000 t
One bridge bucket chain type reclaimer with the capacity of 800t/h is envisaged
for mixed limestone blending stockpile. A hopper will be used to deal with the
mixed limestone at the emergency case. One side reclaimer with the capacity
200tph is used for pure limestone and clay as corrective material. Laterite also
loaded by the side reclaimer. 3.4.1.3 Raw material proportion station
The raw material will be proportioned in this department with bins. Weigh
feeders will be provided to control the raw material proportion.
3.4.1.4 Raw materials grinding (VRM) & exhaust-gas treatment
Vertical Roller Mill (VRM) of capacity 450t/h will be used for drying and grinding
of raw materials. The high-temperature gas from the preheater is used as
drying heat source.
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The VRM will be equipped with high efficiency dynamic separator. The ground
raw meal will be air swept and collected through the high efficiency low-
pressure drop cyclones. The mill will be equipped with bucket elevator for
external recirculation. Product fineness will be 10% residue on 90-micron sieve
with a moisture content of not more than 1%.
Ground raw meal will be transported to the top of homogenizing silo with the
help of air slides and belt bucket elevator. Vent gases from the raw mill circuit,
shall be dedusted in a bag house and the dust content in exhaust gas after
filter will be less than 30 mg/Nm3(dry). Automatic sampler will be provided for the homogenizing silo feeding.
A “kiln dust” handling system will be provided to handle “kiln dust” during direct operation i.e. when raw mill is off. During direct operation, kiln dust collected in bag house, will be transported to “Kiln Dust Bin” by conveyors. Kiln dust shall be extracted in controlled quantity with the help of rotary feeder. Kiln dust extracted from the “Kiln Dust Bin” with the capacity 100m3 will be fed either to “Silo Feed” or to “Kiln Feed”.
An gas conditioning tower will be provided for the preheater gas cooling during
direct operation. One ID fan will be provided after the GCT for the negative
pressure supply. During the stop of the raw mill (directive operation), the kiln
gas will directly enter bag house after cooled down by conditioning tower. The
gas temperature is kept within the allowable range for bag house by automatic
control of water spray amount.
The ID fan and bag house exhaust fan will be speed adjustable type.
3.4.1.5 Raw meal silo & kiln feeding system
One Φ22.5m continuous homogenizing silos with capacity of 20,000 t will be
considered for storing and homogenizing of raw meal.
A kiln feed bin of the 80m3 capacity is envisaged at the bottom the silo. Material from kiln feed bin shall be extracted through a set of shut off gates and dosing valves. Two extraction systems will be arranged at the bottom of the bin. The material shall be weighed through a flow meter and a rotary feeder.
The kiln feeding bucket elevator is belt type. It will lift the raw meal to preheater
top. Raw meal can be sent back the silo from the kiln feeding elevator by a
long chute.
3.4.1.6 Preheater, Kiln & Cooler
The pyro-processing system has been designed to suit 6,000 tpd of clinker
production.
The raw meal shall be burned to clinker in a four-stage double string preheater,
a online precalciner with low NOx emissions and Φ5.0×74m (L/D=14.8) three-
support rotary kiln.
The preheater cyclones were skillfully designed. This series of preheater cyclones has been proved to have following features: low pressure drop, high
efficiency, anti-clogged. The designed online precalciner is easy to be
operated.
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Rotary kiln system is equipped with a variable speed drive, self-aligning
support rollers and one automatic axial hydraulic thrust device. Kiln inlet seal is
of pneumatic cylinder type while outlet seal is of the steel laminar type. Kiln
shell sintering zone is cooled with movable fans mounted on rails. The clinker cooler is a new generation with air-control cooling system. Reciprocating grate cooler is designed and suitable for 6,000 tpd production
level. Clinker transport pan conveyor is used to collect spillage under the
cooler.
A sized electrostatic precipitator is used to de-dust the entire clinker cooler
exhaust. The cleaned gases after ESP, contain less than 30 mg/Nm3. 3.4.1.7 Clinker storage & conveying
A pan conveyor is envisaged for collection of clinker from cooler. A two-way
chute is envisaged at the discharge of the pan conveyor for diverting unburned
clinker into Off-spec clinker bin which capacity is 150 t. Normal clinker is
transported to clinker silo for clinker storage.
Underneath the Off-spec clinker silo, there will be a belt conveyor to sent the
unburned clinker to the proportion clinker bin.
One Φ40m clinker silo will be provided for clinker storage with effective
capacity of 50,000t.
Automatic clinker sampler will be provided on the top of the clinker silo.
Via belt conveyors, the clinker will be sent to cement proportion clinker bins. 3.4.1.8 Gypsum/Additive Crushing & Preblending
Gypsum will be crushed in the plant. A single hammer type crusher with the
capacity of 200t/h will be provided for the gypsum crushing, the additive (HG
limestone) will be crushed by this crusher also. The product will be 85% <
25mm. The crushed material will be sent to the preblending stockpile by belt
conveyors.
The gypsum/additive preblending will have four stockpiles, The blending
stockpile capacity is described as following:
Gyspum : 1 x 10,000 t
HG Limestone : 2 x 5,000 t
The stacker capacity is 200t/h. A side type reclaimer with the capacity of 260t/h
will be provided. The reclaimed material (Gypsum and HG) will be sent to the
cement proportion station by belt conveyors.
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3.4.1.9 Cement Manufacture
Three bins are envisaged for the clinker proportion. The material and capacity
is described as following:
Clinker : 1x300 t
Gypsum : 1x140 t
Additives : 1x300 t
For extraction system, weigh feeder will be provide with needle gate to control
the material proportion. Mixed material will be sent to the cement mill by belt
conveyor.
The cement mill systems with the capacity of 2x160t/h and 3,200 Blaine will be
provided for the product line.
Mixed material will sent to the mill by belt conveyor, on the belt, magnetic
separator and metal detector will be provided to protect the mill liner. Cement
mill is two system, each system is roller press add tube mill, Fine product will
be sent to the cement silo by air slide and bucket elevator. 3.4.1.10 Cement Storage & Bulk Loading
Cement from the mill can be sent to every silo by one bucket elevator.
Two Ф18m cement silo are envisaged for the plant. The capacity of each silo is 10,000t. Air slides will be used for the silo inlet and outlet. Aeration discharge
system will be supplied for silo bottom. Cement form each silo can be sent to
every packer.
one cement bulk loading system are envisaged at the side of a silo. It has the
capacity of 150t/h. Under the bulk loader, there will be a bridge weiger to
interlink and control the cement bulk loader.
Two big bag packing system are envisaged at the side of the other silo. One
capacity is 1t x 30 bags/h. The other is 1.5t x 25 bags/h. Cement is first fed to
the aeration discharge bin, and then separately to the two big bag packers.
A passenger elevator with the capacity 1t will be supplied for the silo and the
packing plant. 3.4.1.11 Cement Packing Plant
Cement from silos is sent to bucket elevator and then to the vibrating
screen/intermediate bin/packer. Four 120t/h packers are envisaged for the
cement packing. For each packer, two semi-auto truck loaders are envisaged.
The truck loaders capacity will suitable for the packers. 3.4.1.12 Coal preblending &conveying
A hopper will be provided for the coal dumping. An apron feeder under the
hopper is envisaged. After the apron feeder, a belt will be used to send the coal
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directly to stockpile. A luffing type stacker with capacity of 300t/h is envisaged. A side type
reclaimer will be supplied with capacity of 100t/h. The reclaimed coal will be
sent to coal mill bin by belt conveyors. 3.4.1.13 Coal Grinding
A vertical mill with capacity of 50t/h is envisaged.
The coal grinding plant will be provided with de-dusting filters, explosion proof
valves on ducts, main filter.
The brief technical details of the mill drying & grinding system are as follows:
2 steel feed bins of 100 t capacity is considered for coal storage.
2 weigh feeder has been considered for coal extraction.
Hot gases from cooler will be used for drying coal in the mill.
Hot gas generator is included.
The mill system will consist of CO2/N2 system for fire protection.
Bag filter has been considered for product collection. Finished product will be
collected from the bag filter shall be transported to two nos. 100 t fine coal
hoppers, which shall be used for firing in the kiln and precalciner separately.
Modern weigh feeders are envisaged for coal powder dosing and transport
system. 3.4.2 Main Equipment List
Department Equipment name Specification Qty
Weight(t)
Preparation of Main Capacity: 1000 t/h(limestone) 1
Raw Materials apron conveyor
Capacity: 300 t/h(clay) 1
Crusher Capacity: 1300 t/h 1
Stacker Capacity:1300 t/h 1 ~155
Reclaimer Capacity:800t/h(limestone mix) 1
Reclaimer Capacity:200t/h(corrective) 1
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Department Equipment name Specification Qty
Weight(t)
Raw Meal Vertical raw mill Capacity : 450 t/h 1
Preparation Feed size : ≤110mm
Fineness: ≤10% ( R 90μm)
Product moisture: ≤1%
Motor Power : 4,400kW 1
Mill fan Capacity : 800,000m3/h 1
Pressure :12,000Pa
Motor Power: --kW
Gas conditioning Capacity : 992,520m3/h 1
tower
ID fan Capacity : 750,000m3/h 1
Pressure : 7,200Pa
Motor Power: --kW 1
Bag house Capacity : 950,000m3/h 1
Temp. : 100℃-mill on
200℃-mill off
Outlet dust content:≤30mg/ Nm3
Bag house fan Capacity: 950,000m3/h 1
Pressure: 4,000Pa
Belt bucket Capacity : 600t/h 1
elevator for silo Height : ~72.7m
inlet Power: ~280kW
Belt bucket Capacity : 460t/h 2 One
elevator for kiln Height : ~92.5m standby
feeding Power: ~200kW
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Department Equipment name Specification Qty
Weight(t)
Clinker Preheater and Capacity :6,000t/d 1 ~766
manufacture precalciner Cyclone :
C1 :4-Φ5,400mm
C2 :2-Φ7,4 00mm
C3 :2-Φ7,400mm
C4 :2-Φ7,600mm
C5 :2-Φ7,600mm
Precalciner:Φ7,800×35,000mm
Rotary kiln Φ5×74m 1 ~883
Capacity :6,000t/d
Piers :3
Inclination: 4%
Speed :0.35~4 r/min
Motor Power:710kW 1
Tertiary air duct Φ3,200mm 1 ~110
Clinker cooler Capacity : 6,000t/d 1 ~400
Cooling area : ~150m2
Inlet temp.:1400℃
Outlet temp. : 65C+amb. temp.
Drive Motor Power: 90kW 4
Clinker crusher 1
ESP Capacity : 700,000m3/h 1
Temp. : 250℃-normal
450℃-Max
Outlet dust content:≤30mg/ Nm3
ESP fan Capacity: 700,000m3/h 1
Pressure: 3,000Pa
Motor Power: 710kW 1
Pan conveyor Capacity: 500 t/h 1
Inclination: 38o
Cement Cement mill 1600x1400 2
manufacture Roller press Capacity: 600 ~750t/h
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Department Equipment name Specification Qty
Weight(t)
Φ4.2x14 2
tube mill
Capacity: 160 t/h
Fineness: 3200cm2/g Blaine
Power:
Cement Packer Capacity: 120t/h 4
dispatch Big bag packer
Capacity: 1tx30Bags/h 1
Capacity: 1.5tx25Bags/h 1
Semi-auto truck Capacity: 120t/h 8
loader
Coal grinding Feed size : ≤50mm 1
Capacity: 50t/h
Coal mill Fineness: ≤12% ( R 90μm)
Product moisture:1%
Main Motor Power : 600kW 1
Bag filter
Capacity: 135, 000m3/h 1 Outlet dust content:≤30mg/
Nm3
Capacity: 143,600m3/h 1
Fan Pressure: 9,200Pa
Motor Power: 470kW 1
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3.4.3 Storage of various materials
No. Material Silo size (m) Reserve(t) Remarks
Raw material storage
Limestone/clay 340m 2x35,000+ Long
1
Laterite 3x5,000 stockpile
Gypsum/ HG 230m 1x10,000
/2x5,000
Coal 240m 2x15,000
2 Raw Material proportion station
Limestone/clay 1-Φ8 1x900 Steel
Laterite 1-Φ4 1x300 Steel
Limestone 1-Φ4 1x200 Steel
No. Material Silo size (m) Reserve(t) Remarks
Clay 1-Φ4 1x200 Steel
3 Raw meal silo 1-Φ22.5 20,000 Concrete
4 Clinker silo 1-Φ40 2-50,000 Concrete
Off-spec clinker silo 1-Φ4 1×150 Concrete
Cement proportion station
5
Clinker 1-Φ6 1x300 Steel
Additive 1-Φ6 1x300 Steel
Gypsum 1-Φ5 1x140 Steel
6 Cement silo 2-Φ18 2x10,000 Concrete 3.5 GENERAL PLANT SERVICES 3.5.1 Compressed Air and air pipe line
One high pressure compressed air stations will be envisaged for the project. 5 units (one stand-by) compressors (20m3/min , 0.75MPa) will be set in the compressed air station.
The compressor(s) shall be screw, only water cooled compressors shall be
offered. Air dryers of refrigeration type and suitable capacity shall be
provided to remove the excess moisture in the compressed air and to ensure
that service air quality meets the specified requirements. Air drier shall be
provided individually for each compressor.
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The Compressed air pipe lines shall be above ground level (overhead) with
central header system and off take to branches regulated through adequately
sized air receivers. 3.5.2 Weigh bridge
There are two weigh-bridges which are setup at the entrance of road to
weigh the goods such as coal, gypsum, and bagged cement etc... There is
one weigh-bridge is setup under the cement silo to weigh bulk cement.
The capacity of all weigh-bridges is 100t. They are all above the level. 3.5.3 Mechanical and electrical workshop
The design principle of this workshop mainly accord with the related guideline of our state and refer to some regulations of mechanical repair of cement enterprises. The workshop belongs to middle scale. It only undertake
repair of middle and small scale of equipment for production and transportation in this plant. It can make some spare parts of process
equipment and also can undertake some rebuilding tasks. Machining pieces, forging pieces, steel-casting pieces, iron-casting pieces, heat-treatment pieces and standard parts needed by the plant shall be purchased.
The plant is supplied with mechanical and electrical workshop. In view of the
low value in use of the equipment of workshops of forging, casting and heat-
treatment and serious pollution, the plant isn’t supplied with workshops of
forging, casting and heat-treatment.
Mechanical and electrical workshop contains four working zones (electrical workshop, machining zone, assembly zone and riveting and welding zone) together with tool room and so on. The major span is 15 meters and the sub-span is 6 meters. The area of the workshop is 1260 square meters with the length of 60 meters and one span is for electrical repair. The major span is supplied with one crane with capacity of 10 tons and elevation of 7.5 meters. Machining zone is supplied with horizontal lathe CW61100C, horizontal lathe CW6163C, horizontal lathe CD6140A, shaping machine BS6065, hydraulic shaping machine BYS60100, slotting machine B5032D,universal knee-type milling machine X6140, portable double column planning machine BQ2012C, radial drilling machine ZA3025×10 and Z3063×20/1, etc.
Assembly zone mainly undertake arranged repair, temporary failure repair and the assembling of spare parts. Riveting and welding zone contains normal machining zone and welding zone. Normal machining zone is supplied with tri-roller plate bender CDW11-20 ×2000B, hydraulic press YQ32-100 and so on. Welding zone is supplied with AC and DC welding sets. The welding sets not only can meet the welding of this workshop, but also some of them can be placed in other related production workshop for temporary repair. In addition, the workshop is also supplied with windlasses of capacity of 5 tons and 8 tons, hydraulic jacks of capacity of 50 tons, 100 tons and 200 tons, hand chain blocks of capacity of 5 tons and 10 tons. They are used by the whole plant and they undertake the lifting of equipment during repair, inner movement, loading and unloading of spares parts and material.
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3.6 Civil Works 3.6.1 Code
Chinese Code shall apply for the civil Design, English version of Codes
listed below will be provided to the Employer.
Code for Design of Masonry Structures GB 50003-2001
Code for design of building foundation GB 50007-2002
Load Code for the Design of Building Structure GB 50009-2001
Code for Design of Concrete Structures GB 50010-2002
Code for Seismic Design of Buildings GB 50011-2001
Code for Design of Steel Structures GB 50017-2003
Code for Design of Reinforced Concrete Silos GB 50077-2003
Code for Design of Architectural Fire Extinguisher Distribution GBJ 140-
90 3.6.2 Subsoil Conditions
Ground bearing capacity: Assumed that the bearing stratum (2.0m~3.0m below the ground) is medium hard stratum and characteristic value of foundation bearing capacity fak = 450kPa.
The detailed supplementary soil investigation will be carried out by the
Owner. The layout plan of boreholes will be supplied by the Contractor. The
quantities of the base will be changed according to the detailed report on
geotechnical investigation. 3.6.3 Other Local Conditions
Max. wind velocity(m/s) 33.5 m/s, Measuring Code: BS Seismic fortification intensity:no consideration for earthquake
resistance.
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3.6. 4 Construction Design
List of buildings and structures:
Buildings and structures Structural type
Crusher Reinforced concrete &
steel
conveyer steel Limestone & shale mixture material
prebiending steel
Coal preblending steel
Gypsum & additive materials stockpile steel
Raw mill steel
Raw meal silo Reinforced concrete
Preheater
Blow second floor Reinforced concrete
Above second floor Steel
Kiln Reinforced concrete
Cooler Reinforced concrete &
steel
Clink silo
Wall Reinforced concrete
ceiling Steel
Proportioning station Reinforced concrete &
steel
Cement mill Steel
Cement silo
Wall Reinforced concrete
ceiling Composite structure
Cement packing
Reinforced concrete & steel
Accessory building Reinforced concrete
frame
3.6. 5 Architecture Design
3.6.5.1 Design basis
While complying with Chinese current specifications and standards of architectural design in the architectural design and trying to adopting new
technology, new materials, advanced and reliable architectural structure, we will take full considerations upon the architectural integrity and endemicity and environmental harmony of the architecture in order to create a new
architectural image boasting senses of the times and local features as well, which satisfies the requirements of reasonable layouts, beautiful shape and style and color harmonization.
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Because the specific layouts and environmental features of the project is
definite, design will be guaranteed that the soundproof and the dustproof of
the construction can satisfy the requirements of relevant specifications, in
which the natural and climate features of the site, skillful architecture design
methods, structural type, architectural modeling and construction cost will be
taken into full consideration. 3.6.5.2 Construction practice (1) Roof works
Roof drainage: free fall for all the roofs of the workshop
Roof slope of the cast-in-place reinforced concrete is 3%.
Water proofing of Roof
All concrete roofs shall be provided with a water proof treatment which shall stand guarantee for minimum seven years. Down take rain water pipe shall
be provided for Control Building and Canteen roof with parapet wall and free fall for substations, compressor house and the like. Colform system from Germany along with Screed concrete or equivalent system of roof water
proofing shall be considered.
Roof Insulation Minimum 50 mm thick high quality thermal wool roof insulation shall be
provided on the underside of roof of Control Building, offices, canteen and
the like for effective air conditioning. The insulation shall be fixed to the
underside of the roof with suitable adhesives. In addition support shall be
provided with GI chicken wire mesh and GI wires nailed to the roof to keep the insulation intact as may be approved by the Engineer.
(2) Flooring and Wall Tiling
Flooring for Control Building, Canteen and Offices shall be with approved
quality granite from China of size 60cm x 60cm x 20mm thick. In other areas
such as Electrical rooms, Toilets, Rest Rooms etc., 30cm x 30 cm vitrified
floor tiles shall be used. Walls of Toilets (WC and Bath/ Shower) shall be
provided with approved quality glazed tiles up to door height or false ceiling
height as appropriate. Process buildings, Stores, Workshops and the like
shall have integral concrete floor with smooth trowel finish using power trowel. External floor surfaces/ ramps shall be broom finish for anti slippery.
External faces of buildings shall be provided with 75 cm wide plain concrete
plinth protection at the finished ground level.
Raised flooring shall be provided in the Control Room and Laboratory as per
requirement of approved quality and make. Adjustable jacks with galvanized
channel shall be used for grid work and Pressed steel board with concrete
infill (sandwich panel) shall be used as floor tile with anti static anti skid
topping. The floor shall be capable of taking 2200kg/ sqm load.
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(3) Wall
Solid concrete block masonry shall be used for below plinth level and hollow
concrete block masonry shall be used for above plinth level. Thickness of
external walls shall be 225mm and for internal partition walls 150mm or as
directed by the Engineer. The strength of the blocks shall not be less than
7N/sqmm. Mortar for masonry work shall be 1:5 cement: sand. The
minimum weight of the hollow concrete blocks shall be as follows:
Block 460 L x 230 W x 230 H: 26 Kgs.
Block 460 L x 150 W x 230 H: 20.Kgs.
Block 500 L x 115 W x 230 H: 20 Kgs. (4) Doors
Solid core flush wooden door with both face lamination shall be used for
offices. The thickness of the door shutter shall be 45 mm, frame shall be
made from well seasoned hard wood of matching quality as of the door
shutter and joints shall be covered with timber architrave.
External Doors for Control Building, Canteen and Offices etc. shall be
bronze anodized aluminum panel with fully glazed/ partly glazed (5.5mm
thick tinted reflective glass) as per the Engineers approval. The extruded
section for door frame shall be made from minimum 3.15mm thick section
and that for the shutter frame shall be from 2.5mm thick section.
Factory made Steel Door (flush door) shall be used in process buildings
such as substations, compressor house, water treatment plant, workshop,
store,
external toilet blocks etc. Sliding Steel Door/ Folding Steel Door may be used where size of the Door is Large (single panel size above 1200mm width). Steel Doors shall be painted with two coats of synthetic enamel paint over a
coat of primer of Berger or equivalent make. Rubber sealing for air tightness and viewing glass panel is to be provided in the Door as per the Engineers
direction. PVC doors may be used for WC and bathroom/ shower (internal doors only) as approved by the Engineer. Transformer rooms shall have steel doors with louvers for proper ventilation.
All Doors shall be fitted with necessary accessories of approved quality like
heavy duty hinges, handles. Door bolts, mortice lock, bottom threshold
wherever needed, floor spring, hydraulic door closer etc. complete. (5) Windows and Ventilators
Windows and Ventilators in the substations and compressor rooms and the
like shall be of mild steel composite section with guard bars. The louver
glass shall be wired glass 5.5mm thick and plane glass shall be 4mm thick.
MS frame and guard bars shall be painted with two coats of synthetic enamel
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paint over a coat of primer of Berger or equivalent make. All rooms, toilets,
bathroom etc. shall be well ventilated with adequate provision of windows
and ventilators. Electric powered exhaust fans shall be provided in toilets
and other places as per the Engineers direction for proper ventilation. 3.7 Water Supply, Treatment and Distribution 3.7.1 Water source
Water demand for the project shall be met from ground water sources. 3.7.2 Water treatment
The water will be pumped from the source to the plant’s raw water reservoir(2×3,000 m3,RCC tanks). Water treatment plant shall be provided by the contractor; complete in all respects with requisite filtration and soften treatment facilities.Treated raw water will be stored in storage tanks of 2×1000 m3 capacity and will then be pumped to circulation water tanks and for process water supply.The drinking water for plant and housing will be disinfected by NaClO to meet the health requirements for use by human beings and stored in potable water tank of 300 m3 capacity. The industrial water will be treated with inhibitors against the aggradation of CaCO3&MgCO3 on the inner surface of the water pipelines and stored in the circulation water tank of 2×400 m3 capacity.
3.7.3 Water supply system The plant will have 4 water supply systems:
a) The water supply for water circulation system
In order to save water, cooling water for production equipment will be circulated. Cooling water will be supplied to production equipments through circulation pump from cold water tank of 400m3 capacity,and the water will be returned to warm water tank of 400m 3 capacity by water return pump .Then the warm water will be sent to cooling tower by warm water pump. After being cooled down, the water will flow back to the cold water tank. The circulation water will be treated by filter to protect the water quality from changing worse. The water circulation rate is about 97%.
b) The process water supply
Water process for raw mill, cement mill etc will come in a independent pipelines network from the treated water tank 2×1000 m3 capacity. Where water needs high pressure such as water spraying for mills, water pumps and tanks will be adopted for secondary pressurization.
c) The living water supply
The potable water tank of 300 m3 capacity will have to be constructed, where the water will have to be disinfected by NaClO. The drinking water for plant and housing will be conveyed from the potable water tank by an independent pipelines. A water tower of 100 m3 capacity will set in pipelines.
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d) The fire fighting water supply The fire fighting water will pressurized from the raw water reservoir of 2X3000 m3 capacity by high pressure fire pumps operated with separate diesel engine. A suitable high pressure fire hydrant system will consist of suitable number of fire hydrants covering entire plant area, passing through all the plant and buildings. The water supply pipe net by the side of roads and in some departments is to
be in circle .The pipe diameter should not be less than DN100 and the
distance between two adjacent fire hydrants should be less than 120m. 3.7.4 Water sewage and drainage system
The sewer lines and drainage lines have to be
distinct. a) Water sewage system
The sewage water will be treated and re-used for water spraying,grass &
ornamental areas.
b) Water drainage system
Open channels will be for rain storm and at some section there will be cover
for the channels. 3.8 Quality Control
Facilities and equipment have to be provided for the control of the raw
materials, intermediate and final products. This comprises of analysers,
samplers, sample transport where required, testing equipment including the
complete equipment of the chemical and physical laboratory. 3.8.1 Raw Materials
one on-line material analyzers are offered for control of raw materials. One
are in the quarry, the other are in the plant. The analyzer is γ-ray analyzer. 3.8.2 Raw Meal
Sampling is from the raw mill to the homogenizing silo. 3.8.3 Kiln Feeding
Sampling is from the homogenizing silo to the kiln feed device. 3.8.4 Clinker
Sampling is in the clinker.
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3.8.5 Cement
Sampling is the cement mill to cement silo. 3.8.6 Laboratory
The laboratory will be equipped for automated testing of major process
related materials, for manual sample preparation as well as for manual
chemical and physical testing.
The equipment will include testing facilities required for meeting out ASTM
standards for the cement plant both for chemical testing as well as physical
testing.
The systems capacity is sufficient for the following maximum testing
frequencies:
♦ Raw Meal : 3 samples per hour
♦ Kiln feed : 1 sample per hour
♦ Clinker : 1 sample per hour
♦ Cement : 1 sample per hour
♦ Manual input : 2 samples per hour
3.9 Fire Extinguishing Equipment
The fire fighting water will pressurized from the raw water reservoir of 2X3000 m3 capacity by high pressure fire pumps operated with separate diesel engine. A suitable high pressure fire hydrant system will consist of suitable number of fire hydrants covering entire plant area, passing through all the plant and buildings.
The water supply pipe net by the side of roads and in some departments is to
be in circle .The pipe diameter should not be less than DN100 and the
distance between two adjacent fire hydrants should be less than 120m.
It will be supplied 2 fire engines (each with 4 tons water tank) in the plant.
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3.10 POWER SUPPLY & DISTRIBUTION 3.10.1 POWER SUPPLY & DISTRIBUTION 3.10.1.1 POWER SUPPLY
In the plant, one 11kV own power plant will be constructed.
Mean while, a 415V diesel generator (1.0MW) for emergency power supply
is set for the plant to guarantee the consumption of level 1 section, such as
kiln auxiliary drive, cooler fan, primary fan, computer system, fire extinguish
water pump as well as the emergency lighting etc. 3.10.1.2 MIAN SUBSTATION
The generator sets are connected dividedly into the network through Single
11kV busbar in mean time. 11kV busbar is employed in the general
distribution station and power received in distributions located in each
section of the plant at 11kV from the general distribution station. 3.10.1.3 11kV DISTRIBUTION STATION
Two stage radial-type power distributing is used in the 11kV distribution
system, i.e. general distribution station supply to substation in each
department in 11kV, and then it is distributed from the substations to each
MV motor and the transformer of each electric room in radial shape.
11kV substations are set as follows:
(1)Raw mill distribution
Scope of supply: MV motor and transformers of electric rooms of auxiliary
materials crushing and stockpile, limestone preblending stockpile, raw
materials proportioning silo, raw mill, exhaust gas treatment and kiln system.
It is planned to be located beside the EP for exhaust gas treatment.
(2)Cement mill distribution
Scope of supply: MV motors and transformers of electric rooms of clinker silo
bottom, cement mill, cement storage and packing system, the campus of the
plant. It is planned to be located beside the cement mill.
(3)Cooler distribution
Scope of supply: MV motors and transformers of electric rooms of clooer. It
is planned to be located beside the EP of cooler .
(4)Limestone crushing distribution
Scope of supply: MV motors and transformers of electric rooms of limestone
crushing and conveying. It is planned to be located beside the limestone
crushing.
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3.10.1.4 LEVEL OF VOLTAGE
Operation power supply: 11kV
Emergency power supply: 415kV
MV distribution : 11kV
MV motor: 11kV
DC operation power: 110V DC
LV motor: 0.415kV
Lighting system: 220V AC
Control system: 220V AC/DC 24V
Maintenance lighting system: 36/12V 3.10.1.5 SELECTION, OPERATON & MONITORING OF MAIN ELECTRIC EUIPMENT
Selection of main 11kV electric equipment:
(1) Selection of the main electric equipment:
11kV distribution system employs metal clad switchboard cabinet which is
equipped with vacuum breaker.
(2) Operation and monitoring
The 11 kV motor loop is controlled by CCR, while local control mode will be
used in emergency cases. In local control mode, the switchgear is opened or
closed by local control push button; distribution loop is controlled by
switchgear cabinet, the operation status is not only indicated on switchgear
cabinet, but also transferred to computer control system, to be monitored by
CCR. 3.10.1.6 RELAY PROTECION
(1) 11kV connection lead in loop:27G, 32G, 40, 59G, 51, G, 64, 64N, 81G,
86, 87G.
(2) 11kV lead in loop: 27, 59, 49, 50, 51, 50G, 51G.
(3)11kV feeder loop: 49, 50, 51, 50G, 51G.
(4)11kV transformer loop: 49, 50, 51, 50G, 51G, 94, 260.
(5)11kV MV motor loop: 49, 50, 51, 50G, 51G, 46, 51L, 51R, 66, 47, 87.
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3.10.1.7 MEASUREMENT
Multi-function electricical instruments are set in the 11kV loop for inspection
of current, voltage, active power, non-active power, power factor and
frequency etc. 3.10.1.8 POWER FACTOR COMPENSATION
Automatic compensation panels is set to LV 440V busbar side;
11KV Automatic compensation panels shall be connected with the MV slip
ring motors, while it will be started/ stopped in synchronism with motors.
Power factor is compensated to MV variable frequency motor through
variable frequency control system.
In normal production the power factor at 11kV side will reach 0.90 or above. 3.10.2 SETTING OF ELECTRIC ROOM & THE CONTROL METHOD 3.10.2.1 The electrical rooms are:
(1) Limestone crushing electrical room:
(by the limestone crushing
department) Supply scope: Limestone
crushing etc. Control :by computer
(2) Limestone stockpile electric room:
(by the limestone preblending stockpile)
Supply scope:limestone preblending stockpile etc.
Control:by computer
(3) Raw materials grinding electric room:
(beside the EP of exhaust gas treatment)
Supply scope :Raw mill & exhaust gases treatment, top of raw meal
homogenization silo, conditioning tower and the bottom of the raw meal bin.
Control:by computer
(4) Preheater electric room: (set under the preheater tower)
Supply scope:bottom of raw meal silo, preheater, kiln and by-pass.
Control:by computer
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(5) Cooler electric room:
(under the EP of cooler)
Supply scope:from cooler and EP of cooler to the top of clinker silo.
Control:by computer
(6) Cement mill electric room:
(set at the two sides of cement grinding department)
Supply scope:from cement mill bin, cement grinding, top of cement silo, to
clinker silo and clinker conveying and the compressor.
Control:by computer
(7) Cement packing electric room:
(by the cement packing workshop)
Supply scope: from cement packing to the bottom of cement silo and bulk
loading.
Control: by computer
(8) Auxiliary electric room:
(by the recycling pump house)
Supply scope: from water supply, potable water pool and pump house,
recycling water pool and pump house to fuel oil storage and conveying.
Control: by computer
(9) plant utility electric room:
(beside the administrative building)
Supply scope: administrative building. 3.10.2.2 LV service wire will connect the electric rooms. 3.10.3 POWER SUPPLY & DISTRIBUTION CIRCUIT
Copper core will be used for electrical and control cable in this project
Polyvinyl chloride insulated power cable will be used for electrical cable.
To adopt three cores YJV22-8.7/15 (3 phases ) cable for 11kV 3 phase
electric equipment.
To adopt four cores YJV-0.6/1 (3 phases + PE) cable for 415V 3 phase
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electric equipment.
To adopt five cores YJV-0.6/1 (3 phases +N+ PE) cable for 415V electric
equipment.
Control cable: KVV-0.5 1.5mm2 series cable
Instrument signal cable: DJYP2V 1.0mm2 shielded cable
Control cable to DCS: KVVP-0.5 1.0mm2 shielded control cable
This project adopts cable trench and cable tray or direct embedding to cable
connection between power plant, distribution stations, CCR and electric
rooms. For cable connection inner department, combination of cable tray, Cable trench and through-pipe methods is used. Special cable tray separate
laying is for communication cable of computer control system .All cable trays should be connected electrically and grounded reliably. Cable trays will be laid as close as possible to buildings, channels or corridors A method of direct embedding along street of armoured cable is used for
street lamps cable laying. 3.10.4 LIGHTNING STRIKING PROTECTION & GROUNDING SYSTEM
(1)Lightning striking protection devices will be installed according
specification of related standards.
(2)Grounding system: 11kV system will be ground and TN-S system will be
used for earthing of 415V LV distribution.
Grounding devices at each posts in the plant will be connected into a network
by galvanized flat steel. 3.10.5 1 ELECTRIC DRIVE OF DEPT. 3.10.5.1 1 Power supply system of dept.
11kV power supply from each distribution in the plant provide power source
to MV motors in workshops and transformers in electric rooms. LV equipment
and motors are directly powered by electric rooms in main workshops. 3.10.5.2 Control scheme
Main process equipment are controlled by computer system with the control
mode “local” and “central”.
An button box will be set beside the equipment controlled by computer, which
is normally comprised with “Start” and “Stop” buttons to really local control. In
the local mode, we can start or stop the equipment for test or maintenance
safely. It is important that the “Stop” is prior.
In the central control mode, all the electric equipments will be controlled by
the computer control system according to the program which covering the
process line and equipment protection requirement.
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3.10.5.3 Selection of motors and control devices
(1)Selection of motors and start methods
11kV MV motor is used for equipments with capacity above 300kW, while
415V LV motor for those below 300kW. Winding motor or squirrel cage motor
is chosen according to load. Liquid rheostat starter will be used for winding
motor, while, full voltage direct start is adopted for squirrel cage motor
starting, which is advantageous in investment saving and convenient
installation. . (2) Full digital frequency converter is used for control of motors which needs
speed adjusting. 3.10.6 LV ELECTRIC EQUIPMENT SELECTON
As the LV distribution center, the electric room at workshop will be in-door
arranged. Electric transformer will be S9-M series 112x2.5%/0.44kV type.
D, yn11 will be the main wire method.
LV switchboard is mainly equipped with breaker、contactor and thermal relay
from world-well-know suppliers. 3.10.7 ELECTRIC LIGHTING
Power for lighting is from LV transformer in electric room, power supply is in
3 phases 5 wire system, lighting voltage is 220V and mobile reparation
lighting voltage is 36/12V.
Departments of working will be powered by separate loop, emergency
lighting power supply will be used in case the normal lighting power fails.
General lighting is the main method for department lighting while local
lighting is auxiliary.
Combination lighting of HV natrium lamp or HV mercury lamp is for high
building, or use new energy-saving lighting of large capacity for convenience
of maintenance;
Fluorescent lamp will be installed in duty room, control room and offices.
3.10.8 ELECTRIC REPARATION
The electric reparation is set in CCR, complete set of necessary devices and
instruments and tools will be equipped for small size motors and normal
electric equipment reparation, as for the large size electric equipment
reparation will be sourced outside.
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3.11 AUTOMATION CONTROL 3.11.1 DESIGN PRINCIPLE
(1) Distribution control system (DCS) is adopted for automatic control and
monitoring the procedure from limestone preblending stockpile to top of
cement silo.
(2) Automatic adjusting loop will be set at key posts and raw meal quality
control will be attach much importance while inspection display, alarming &
alarm print and long distance remote control will set for generally.
(3) Other analog signal is converted into 4~20mA standard signal via
transducer and transmitted to I/O modular.
(4) Other DI/DO signals are led in 220V.DC. 3.11.2 AUTOMATION EQUIPMENT SELECTION PRICIPLE
(1) World well known products are employed for Instrumentation of DCS and
examination instrument of key production section..
(2) Distributed control system
The DCS system of this project has several features as follows:
a. Fulfill the process control requirement.
b. Ensure the system running stable & reliable through adopting advanced
hardware and flexible software.
c. A man-machine friendly interface will make the operation very convenient.
d. Guarantee the sufficient storage of spare parts for certain long time use.
e. DCS has a function of communication with MIS network.
(3) Local instrument
Products with good performance and high quality are employed.
(4) Cable
Analog signal transmission will use DJYP2VR series cable (cross-section is
1.0mm2), DI/DO signal transmission will use KVVP-0.5 series cable (cross-section is 1.0 mm2).
3.12.3 COMPUTER CONTROL SYSTEM
Main process sections are controlled integrated and distributed through
distributed computer control system with high reliability and advanced
technology. This system is composed with operator station, local control
station and system communication network.
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Operator station will be set at posts of CCR, control room of cement packing
and limestone crushing. Monitor and control procedure will be fulfill via CRT
and operation board, these procedure will include motor group on/off and
emergency stop; The operation status, ready status, error status and relevant
parameters can be displayed on CRT, the display, setting, alarming, recording and auto-control of technical data of process; printing of the record
of failure alarming and all procedure data via printers.
Local control stations are set in each electric room, so that to fulfill works
such as data collection and processing of DIDO & analog signals , PID loop
control as well as the logic control start/stop etc. 3.11.3.1 Scope of computer control and management
The scope of computer control system is from limestone crushing to cement
packing. 3.11.3.2 Central control room
CCR equipped with three sets operator station, one set engineer station,
there set fuzzy logic system, three sets managing station and the monitoring
device of industry television. Raw meal quality control system is also set in
CCR. 3.11.3.3 Local control station
(1) Local control station of limestone crushing :(set in the electric room of
limestone crushing)
Scope of control: limestone crushing etc.
(2) Local control station of coal mill:
Scope of control: coal crusher ,coal mill
(3) Local control station of raw meal grinding:
Scope of control: raw mill and exhaust gas treatment, top of raw meal
homogenization silo, conditioning tower and bottom of raw material
proportioning station.
(4) Local control station of preheater:
Scope of control: bottom of raw meal silo、preheater/precalciner and kiln
(5) Local control station of cooler:
Scope of control: cooler and EP, tope of clinker silo。
(6) Local control station of water pump house: Scope of control: water pump house, water treatment, circulating water tank
& pump house and potable water tank.
(7) Local control station of cement mill:
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Scope of control: cement grinding, top of cement silo, bottom of clinker silo
and clinker conveying, bulk clinker loading, and gypsum crushing.
(8)Local control station of cement packing:(use small computer system)
Scope of control: cement packing, bottom of cement storage, cement bulk
loading etc. 3.11.4 AUTOMATIC DEVICES & SELECTION
(1) Raw meal quality control system: raw meal quality control system is
composted with sampling device, X-Ray analyzer and computer。
(2) Kiln temperature measuring device: scanning the kiln and showing the
temperature curve as well as the 3-dimension image.
(3) Industry television system: Special industry television device is equipped
at the end of kiln, cooler, inlet of raw mill, inlet of cement mill and preblending
stockpile, so that to supervise the operation situation of the key point in CCR.
(4)Gas analyzer is equipped at preheater to inspect the content of CO, O2,
NOx and supervise the burning condition and relative equipment
(5) Inspection of process condition: It is necessary to set measuring devices
for temperature, pressure, flow, material level, speed inspection, and convey
these signal into computer system, so that the monitor to production
condition can be guaranteed. 3.11.5 CABLE AND EARTHING OF AUTO-CONTROL SYSTEM
Cable for Connecting primary detecting element transducer to each local
control station and cable for DC signal transmission will be with DJYP2VR
screening cable and the cable for AC signal and DIDO transmission will be
KVVPR control cable.
Cable tray, cable trench methods is used for cable laying. It will be laid apart
or separated by baffle with power cable. Cable out of trench or tray will
through-piped.
The signal screen shield will be connected to the screen grounding
connection at one end of panel.
The metal enclosure will be grounded separately to the electric grounding
connection. 3.11.6 INSTRUMENT REPARATION
Instrument reparation locates in the CCR and equipped with necessary
devices for maintenance, examination & reparation and calibration of
common instruments, for the reparation of some special instrument, it will be
responsible by the manufacturer.
PENGFEI – IRD Swiss Project 6000 TPD Clinker
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