As of June 2025, the national cement output was 815 million tons, down 4.3% from the same period last year. The domestic demand for cement continued to decline, and the contradiction between supply and demand became increasingly prominent. Faced with the severe market situation, the key for enterprises to cope with the predicament is to continuously reduce costs and increase efficiency and enhance their competitiveness.
In the cement production process, the grinding system can be called a "big power consumer", which accounts for more than 60% of the power consumption. The problems of high energy consumption and low efficiency have long restricted the process of energy saving and consumption reduction in the cement industry. At present, some cement enterprises have reduced the power consumption of cement grinding to about 20 kilowatt-hours, thus forming a greater cost advantage in the market competition.
From the industry application experience, the cement semi-finished grinding process system has significant advantages in reducing the grinding energy consumption of enterprises.
1. Compared with the traditional combined grinding process system, a roller press with large material handling capacity and a down-inlet double-separation high-efficiency powder concentrator with large feeding and separation capacity must be used, and the V-type powder concentrator and the double-separation high-efficiency powder concentrator share a system fan. A circulating fan, a cyclone dust collector (double cyclone or single cyclone) and part of pipeline and conveying equipment in the combined grinding system are cancelled, the number of equipment and maintenance points are reduced, and the maintenance cost is reduced.
2. In the semi-finished grinding system, the high-concentration bag dust collector is directly used to collect the finished cement products produced by the extrusion of the roller press section and the grinding of the tube mill section, so as to avoid a large amount of < 45 μm fine powder entering the tube mill, resulting in serious adhesion on the surface of the grinding body and the lining plate caused by "over-grinding" in the fine grinding bin. O that the tube mill system always keeps higher and stable grinding efficiency. And
3, the cement finished product is collected by the high-concentration bag-type dust collector, the dust concentration in the subsequent pipeline and the system fan is obviously reduced, the factors causing the serious abrasion of the pipeline and the impeller of the circulating fan in the traditional combined grinding process system are thoroughly eliminated, the abrasion of the system equipment is reduced, the installed power is reduced, The abrasion consumption of that equipment is obviously reduce, and the grinding pow consumption of the whole system is low.
4. The tube mill section of the system can be converted from the closed-circuit grinding process to the open-circuit grinding process, and can also be converted from the open-circuit grinding process to the closed-circuit grinding process, which realizes the flexible conversion and adjustment of a set of grinding system that can be opened and closed, and the conversion operation is simple and fast.
5. In the roller press cement semi-finished grinding process system, when the subsequent tube mill system is operated in the open-circuit mode, that is, the finished products created by the roller press section and the finished products produced by the open-circuit tube mill grinding system are mixed and warehoused, the particle gradation range of the finished products is wider than that in the closed-circuit operation.
6. When the subsequent tube mill system is operated in a closed-circuit mode, that is, the finished product created by the roller press section and the finished product produced by the closed-circuit tube mill grinding system are mixed and put into storage, the particle gradation range of the finished product is still narrower than that of the open-circuit operation, and the sphericity of the cement particles produced by the roller press is very low, and the particle morphology is mostly irregular strips, polygons, etc.
7. The distribution range of cement particles produced by the roller press high-efficiency material bed grinding equipment is relatively concentrated (narrow distribution), that is, the particle size is more uniform, the uniformity coefficient n value increases, the gap between particles increases, the accumulation density of cement powder particles is small, it is difficult to form the most compact accumulation, when the same fluidity is achieved, more water is needed. The water becomes the filler and fills in the gaps and holes between the cement particles, resulting in the increase of the water demand of the cement standard consistency; the higher the grinding efficiency of the cement production system is, the more beneficial it is to increase production and save electricity, but the more prominent the water demand of the finished cement is, which is one of the main reasons for the large water demand of the cement standard consistency in the semi-finished grinding closed-circuit process system.
8. Due to the high content of fine particles less than 5 μm in the cement extruded by the roller press section of the system, the specific surface area and compressive strength of the finished cement are generally high, which creates a prerequisite for the comprehensive utilization of industrial waste residues, the preparation of composite cement with large dosage and the reduction of cement production costs. The system should balance the relationship between the cement performance and the system's high efficiency, production increase, power saving and other aspects, and make corresponding adjustments to the relevant control parameters in the system, the internal structure of the tube mill and the types of mixed materials used, so as to make the performance of the finished cement meet the requirements of concrete preparation.
9. In the system, the tube mill tail is equipped with separate ventilation and dust collection equipment, and the dust collection fan is controlled by variable frequency speed regulation, which is convenient for the adjustment and operation of the ventilation rate in the mill during the production process.
At the same time, combined with the judgment and analysis of intelligent equipment to solve the fluctuation of the field grinding system, it can also make the operation of the cement grinding system more stable. The use of intelligent means to transform the grinding system can improve production efficiency, improve product quality, reduce system energy consumption, promote energy saving and emission reduction, and produce good economic and environmental benefits. Cost
reduction is one of the most effective ways to enhance the competitiveness and profitability of enterprises, in order to accelerate the technological upgrading of the industry and help cement enterprises cope with market challenges. China Cement Network is scheduled to hold the 14th China Cement Energy Conservation and Environmental Protection Technology Exchange Conference and the 6th Intelligent Summit Forum in Zibo, Shandong Province, from September 23 to 24. This conference will bring together industry experts, enterprise representatives and many industry stakeholders to gather group wisdom and promote energy-saving, environmental protection and intelligent transformation and upgrading of the cement industry.
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