Asset List & Delivery List - Zementwerketeam-3000.de/data/documents/Technical-Report-6000TPD_1.pdf · be applied to in the quotation. The preheater, calciner, rotary kiln and some

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


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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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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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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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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.


Page25

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.


Page29

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.


(4) Preheater electric room: (set under the preheater tower)

Supply scope：bottom of raw meal silo, preheater, kiln and by-pass.



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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.


(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.


(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.


Page36

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.


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END of entry

Documents

Asset List & Delivery List - Zementwerketeam-3000.de/data/documents/Technical-Report-6000TPD_1.pdf · be applied to in the quotation. The preheater, calciner, rotary kiln and some