This 4000 tpd cement production line project is built for The National Cement Company (P.S.C.) in Dubai, UAE, NCC has a production capacity of around 1.5 million tons of cement annually.NCC is a Dubai-based company operates within the cement manufacturing sector, serving markets in the UAE and GCC. National Cement manufactures a variety of cement products, contributing to major construction projects across the region. Their headquarters are located on Sheikh Zayed Road in Dubai's Al-Qouz Industrial Area.
What are the Characteristics of this 4000 tpd cement production line?
Ball Mill: Utilize a Φ4.2x13m Ball mill capacities around 150-200 tons per hour. This raw material grinding mill have a motor power rating of 3500-4500 kW. The ball mill is used for raw material grinding.
Vertical roller mill: ZJTL 5640 VRM have a capacity of 225-250 t/h, with a grinding table diameter of 5600 mm and motor power between 4800-5000 kW. This VRMs are favored for energy efficiency, reducing power consumption by about 30%-40% compared to ball mills. Also allow simultaneous drying and grinding of materials with moisture content up to 10%.
Rotray kiln: Kiln size for this cement plant Φ5.2x72m, have a clinker production capacity of 5000-6000 tons per day, with power consumption ranging from 500-800 kW for the main drive. The kiln is critical for the calcination process, where raw materials are heated to high temperatures to produce clinker
What is the process flow of this 4000 tpd cement factory?
- Limestone Crushing and Grinding: Jaw crusher is used to reduce the size of limestone to less than 70mm. Then the Vertical roller mill is configured for efficient raw material grinding.
- Calcination: The five-stage cyclone preheater and Φ5.2m×72m decomposition furnace are used to ensure the effective calcination of clinker.
- Clinker Cooling: The grate cooler is used, the effective area of the grate bed is 85 square meters, and the heat recovery efficiency is as high as 80%.
- Coal Preparation: The Coal pulverizer VRM roller mill is selected to grind coal into powder and then feed to the rotary kiln burner.
- Clinker Grinding: The pre-grinding system, including two Φ1.2m×800mm roller presses and Φ4.2m×13m ball mills, is used to significantly reduce energy consumption.
- DCS Control: The DCS distributed control system is used to realize signal acquisition, testing, monitoring and process parameter control of the production line through the PC control system.
What are the key design parameters?
| Key Parameters | Target Value | Achieved Value |
| Production Capacity (tons/day) | ≥4050 | 4320 |
| Clinker Heat Consumption (kJ/kg-Cl) | ≤3000 | 2998 |
| Clinker Power Usage (kWh per ton) | ≤61 | 57.5 |
| Clinker 28-Day Compressive Strength (MPa) | ≥57.5 | 60 |
| Dust Concentration (mg per Nm³) | ≤95 (Kiln Inlet, Kiln Outlet) | 93 (Kiln Inlet, Kiln Outlet) |
| ≤48 (Other Sections) | 31 (Other Sections) |
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