https://cementl.com/ The 5000 tons per day cement production line is designed to handle multiple raw materials such as limestone, gypsum, slag, GGBFS, and natural pozzolana for the production of both Ordinary Portland Cement (OPC) and Pozzolana Portland Cement (PPC). The line uses a Vertical Roller Mill (VRM) as the main grinding equipment, which allows flexible operation for different feed materials and blending ratios.
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The raw material preparation section includes a limestone crusher with a capacity of 800 tons per hour, a clay and gypsum storage system, and a proportioning belt scale that ensures precise raw mix composition. From there, materials are fed into the vertical roller mill, where grinding pressure of around 150–180 bar is applied between rollers and grinding table. The typical mill output for this line is 450–480 tons per hour, achieving a raw meal fineness of 12–14% residue on 80 μm sieve.
For slag and GGBFS grinding, the same VRM is used with minor adjustments in the nozzle ring opening and hot gas flow. Grinding temperature is kept at 80–90°C to avoid false setting of gypsum. Pozzolana is usually interground with clinker in a separate batch, at a feed ratio of 25–30%, depending on the PPC grade requirement.
The kiln line is sized for 5000 TPD clinker capacity, consisting of a five-stage cyclone preheater with a calciner and a rotary kiln of 4.8 m diameter × 74 m length. Kiln firing uses pulverized coal from a dedicated coal vertical roller mill, with coal fineness at 12% residue on 90 μm sieve. The kiln outlet temperature is controlled around 1450°C to form stable clinker minerals such as alite (C3S) and belite (C2S).
Clinker cooling is handled by a grate cooler with a capacity of 55 t/h and a heat recuperation efficiency of about 68%, which provides hot air back to the kiln and calciner. Clinker temperature after the cooler is reduced to 65°C above ambient, ensuring safe conveying to clinker silos.
In the cement grinding section, the same VRM system is used for blended cement production. Clinker, gypsum, slag, and pozzolana are fed in precise ratios through weigh feeders. For OPC, the gypsum content is kept at 4–5% to control setting time. For PPC, pozzolana addition varies between 25–35%, while slag cement includes 30–40% GGBFS. The cement fineness is targeted at 340–360 m²/kg Blaine for OPC and 380–400 m²/kg for PPC.
Dust collection is achieved by a baghouse filter with 99.9% efficiency, maintaining emission levels below 30 mg/Nm³. The entire plant is operated by a centralized DCS control system, which allows continuous monitoring of mill vibration, kiln draft pressure, and clinker free lime. Power consumption for the whole line averages 92–95 kWh per ton of cement, which is typical for a plant of this scale.
The finished cement is stored in six silos of 10,000 tons each, equipped with air slide conveyors and automatic truck and bulk loading systems. Daily output of 5,000 tons ensures continuous supply for both local construction projects and export demand.
In summary, this 5000 TPD vertical roller mill cement production line integrates limestone, gypsum, slag, GGBFS, and pozzolana to produce high-quality OPC and PPC. With its flexible grinding system, precise raw mix control, and stable kiln operation, the plant ensures consistent product quality and reliable large-scale output.
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