Скачать или смотреть 5000 TPD Portland Cement Production Using Coal Vertical Roller Mill Pulverizer for Fuel Preparation.

https://cementl.com/ The 5000 TPD Portland cement production line uses a coal vertical roller mill pulverizer as the main equipment for fuel preparation. In cement manufacturing, the kiln and calciner require a steady supply of fine coal to maintain stable combustion. Without accurate coal grinding and dosing, the clinker quality and kiln operation can suffer. For this reason, the fuel preparation system is considered as important as raw meal grinding or clinker cooling.

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Coal Receiving and Storage

Coal for this cement plant arrives by truck and is unloaded into a covered stockpile. The daily coal demand for a 5000 TPD line is about 320–350 tons, depending on coal calorific value. A stacker and reclaimer move the material into the feed hoppers. From here, belt conveyors transport the coal to the vertical roller mill feed bin. A magnetic separator and metal detector are installed in the conveying line to remove tramp iron before the coal enters the grinding system.

Grinding and Drying Process

The coal vertical roller mill pulverizer combines crushing, drying, and classification in one unit. Raw coal with a moisture content of up to 12–14% is fed to the mill by a weigh feeder. Hot gases from the preheater or a dedicated hot gas generator pass through the mill to dry the coal. Outlet temperature is maintained between 75–85°C to keep the coal dry without causing ignition.

Inside the mill, the grinding table rotates at about 28–32 rpm, while the rollers exert hydraulic pressure on the material bed. The grinding force fractures the coal into fine powder. A dynamic separator above the mill classifies the particles: fine material is carried with the gas stream, while coarse material falls back to the table for further grinding. The target fineness is 10–12% residue on 90 μm sieve, which ensures complete combustion in the kiln.

Collection and Storage

The fine coal particles are collected in a pulse jet bag filter. Air-to-cloth ratio is kept at about 1.0–1.2 m/min to ensure stable filtration. Collected coal powder is transported by air slides to the fine coal silo. Each silo is equipped with nitrogen purging, CO monitoring, and level indicators. For a 5000 TPD plant, the silo usually has a storage capacity of 1500–2000 tons, equal to about 3–4 days of kiln fuel consumption.

Feeding to Kiln and Calciner

From the fine coal silo, material is extracted by gravimetric weigh feeders. One line supplies the main kiln burner, while another line feeds the calciner burners. The kiln burner consumes around 10–12 tons of coal per hour, while the calciner requires about 3–4 tons per hour. The feeders control flow precisely to maintain steady flame temperature and clinker mineral formation. A steady coal feed avoids large fluctuations in kiln temperature, which can lead to coating build-up or unstable free lime in clinker.

Safety Features

Because coal is a combustible material, safety is built into every step of the system. The mill and bag filter are equipped with CO and temperature sensors. Inert gas (CO₂ or N₂) injection is available for mill purging during startup, shutdown, or emergency stops. Explosion relief doors are installed on ducts and silos. Regular purging and strict housekeeping reduce dust accumulation, which is one of the main fire hazards in coal systems.

Control and Operation

The coal preparation system is operated from the plant’s Distributed Control System (DCS). Operators monitor feed rate, mill differential pressure, separator speed, and bag filter performance. Mill vibration is checked regularly, with alarm limits set at 1.5–2.0 mm/s. Maintenance schedules include roller and table liner replacement every 10,000–11,000 hours depending on coal abrasiveness.



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