Zou Weibin: How Does the Cement Grinding System Sprint to 20 Degrees of Power Consumption!

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. In order to break through this development bottleneck, more and more cement enterprises devote themselves to energy-saving transformation of grinding system. Zou Weibin, senior consultant of

China Cement Network and practical expert of cement grinding, pointed out that if the power consumption of grinding system can be stabilized at about 20 degrees, it can be regarded as the leading level in the industry. However, at present, most domestic cement enterprises have not reached this level, which also means that there is great potential for energy saving and consumption reduction. Even though the cement industry is facing severe challenges, enterprises still need to take the initiative to overcome the problem of energy saving and cost reduction, and achieve the green development goal of "high quality, high yield and low consumption".

Talking about the effective path of energy saving and consumption reduction of the grinding system, Zou Weibin emphatically introduced the remarkable advantages of the cement semi-finished grinding process system:

A roller press with large material processing capacity and a down-inlet double-separation high-efficiency powder concentrator with large feeding and sorting capacity must be adopted, and the V-shaped powder concentrator and the double-separation high-efficiency powder concentrator share a system fan, thus a circulating fan, a cyclone dust collector (double cyclones or single cyclones) and part of pipelines 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 prevent a large amount of < 45 μm fine powder from entering the tube mill. As a result, the grinding body and the surface of the lining plate are seriously adhered to each other due to "over-grinding" in the fine grinding bin, so that the tube mill system always maintains a high 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 warehoused together, the particle gradation range of the finished product is still narrower than that in the open circuit operation, and the sphericity of the cement particles produced by the roller press is very low. The particle morphology is irregular strip, polygonal and so on.

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 is increased, the gap between particles is increased, the packing density of cement powder particles is small, and it is difficult to form the most compact packing. When the same fluidity is achieved, more water needs to be added, and the water becomes a filler to fill the gaps and holes between the cement particles, resulting in an increase in the water demand for the standard consistency of the cement; The higher the grinding efficiency of the cement production system is, the more favorable 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 why the water demand of the cement standard consistency of the semi-finished grinding closed-circuit process system is too large.

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.

In addition, Zou Weibin also said that the fluctuation of on-site grinding system can be solved through the judgment and analysis of intelligent equipment, so that the operation process of cement grinding system is more stable , and the grinding system can be transformed by intelligent means. It can improve production efficiency, improve product quality, reduce system energy consumption, promote energy conservation and emission reduction, and produce good economic and environmental benefits.

In order to accelerate the realization of the "double carbon target" and actively promote the green and high-quality development of the industry, China Cement Network will hold the "2025 China Cement Double Carbon Conference and the 13th Energy Conservation and Environmental Protection Technology Exchange Conference" on May 27-28, 2025. At the same time, the release ceremony of "2025 ESG Ranking List of Cement Industry" was held . This conference will bring together industry elites and multi-resources to provide all-round support for the industry in terms of technology, policy landing and resource docking. At that time, Zou Weibin, senior consultant of China Cement Network and practical expert of cement grinding, will share the theme of "reducing cost and increasing efficiency of cement grinding system".