1. PAINPOINT DRIVE NOLEING

Managing a cement plant’s core material handling and processing systems presents persistent challenges that directly impact your bottom line. Та мэдэрч байна уу:
Хэт их зогсолт: Unplanned stoppages in your preheater or kiln feed system due to equipment failure, costing upwards of $15,000 алдагдсан үйлдвэрлэлд цагт.
Засвар үйлчилгээний өндөр зардал: Байнга, laborintensive maintenance cycles for cyclones, ducts, and coolers, consuming both spare parts budgets and valuable manhours.
Тогтворгүй тэжээл & Чанартай: Fluctuations in raw meal or clinker quality due to unreliable conveying or dosing equipment, leading to offspec product and thermal inefficiency.
Эрчим хүчний үр ашиггүй байдал: Suboptimal heat transfer or excessive pressure drops in preheater towers and calciner strings, inflating your fuel and power costs per ton of clinker.
Rapid Wear & Нөхвөр: Premature failure of critical components exposed to high temperatures and abrasive materials, forcing shorter replacement intervals.

Үйлдвэрийн менежерүүдийн асуулт тодорхой байна: how can you achieve greater operational stability, reduce total cost of ownership, and improve the predictability of your production line?

2. БҮТЭЭГДЭХҮҮНИЙ ТОЙМ

This product line encompasses customengineered Cement Plant Preheater & Calciner Systems. As an ODM manufacturer, we provide complete tower assemblies and key components designed for the pyroprocessing stage of cement manufacturing.

Үйл ажиллагааны ажлын урсгал:
1. Raw Meal Introduction: Prehomogenized raw meal is fed into the topstage cyclone via a pneumatic or mechanical conveying system.
2. GasSolid Heat Exchange: The meal descends through a series of cyclones countercurrent to hot exhaust gases from the rotary kiln, undergoing progressive preheating.
3. Кальцинжуулалт: In the integrated calciner vessel (inline or separateline), ойролцоогоор 9095% of calcination is achieved through efficient fuel combustion before the material enters the kiln.

Хэрэглээний хамрах хүрээ: Suitable for new dryprocess cement line installations and major retrofits aimed at capacity increase or efficiency upgrades.
Хувьсгал: System design is highly specific to plant capacity, fuel type, and raw material characteristics; not an offtheshelf solution.

3. ҮНДСЭН ОНЦЛОГ

LowPressure Drop Cyclone Design | Техникийн үндэслэл: Computational Fluid Dynamics (Хөжиг) optimized geometry | Үйл ажиллагааны ашиг тус: Reduces fan power consumption and overall system pressure drop | ROI нөлөө: Талбайн өгөгдлийг харуулж байна 58% reduction in ID fan energy use yearoveryear.

HighAlumina Refractory Lining System | Техникийн үндэслэл: Proprietary phosphatebonded castables with superior thermomechanical stability | Үйл ажиллагааны ашиг тус: Extends campaign life between major refractory overhauls | ROI нөлөө: Reduces refractory replacement costs and associated downtime by an estimated 1520% per cycle.

Modular Ducting & Housing Construction | Техникийн үндэслэл: Segmented steel plate design with precision flanging | Үйл ажиллагааны ашиг тус: Enables faster field assembly and reduces erection time by weeks | ROI нөлөө: Lowers installation labor costs and accelerates timetoproduction.

MultiPoint Calciner Burner Array | Техникийн үндэслэл: Strategically positioned fuel injection lances with independent air control | Үйл ажиллагааны ашиг тус: Ensures stable, complete combustion with low CO levels across variable load conditions | ROI нөлөө: Improves specific heat consumption efficiency by optimizing fuel burnout.

Advanced Tertiary Air Duct Design | Техникийн үндэслэл: Engineered internal guide vanes to minimize turbulence and erosion hotspots | Үйл ажиллагааны ашиг тус: Provides uniform air distribution to the calciner with reduced wear rates | ROI нөлөө: Decreases maintenance interventions for duct inspection and repair.

Integrated Access & Monitoring Platforms | Техникийн үндэслэл: Structural platforms at all critical inspection points, including thermocouple ports | Үйл ажиллагааны ашиг тус: Your operators can perform safe routine inspections and measurements without scaffolding | ROI нөлөө: Enhances predictive maintenance capabilities and personnel safety.

4. ӨРСӨЛДӨХ ДАВУУ ТАЛУУД

| Гүйцэтгэлийн хэмжүүр | Аж үйлдвэрийн стандарт жишиг | Our Preheater & Calciner Solution | Баримтжуулсан давуу тал |
| : | : | : | : |
| Cyclone Collection Efficiency (Үе шат 1) | 8588% fine meal capture > 90% capture rate across particle sizes
Reduced kiln feed loss |
| Specific Heat Consumption (Тор) ~730 kcal/kg clk ~705 kcal/kg clk
~3.5% improvement in thermal efficiency |
| Галд тэсвэртэй доторлогооны амьдрал (Cyclone Cones) 1824 сар >30 сар
>25% үйлчилгээний хугацаа урт |
| System Pressure Drop (Tower Total) ~7500 Pa <7000 Pa
>6% reduction in fan load |
| OnSite Erection Time (төлөө 5000 tpd tower) ~7 months ~6 months
~14% faster commissioning |

5. ТЕХНИКИЙН ҮЗҮҮЛЭЛТҮҮД

Хүчин чадлын хүрээ: Designed for clinker production lines from 2,500 TPD to 10,000 TPD.
Эрчим хүчний шаардлага: Systemspecific; designed to minimize auxiliary drive and fan power demand.
Материалын үзүүлэлтүүд:
Shell Steel Plate: Q235B / Q345B (ASTM A36 / A572), thickness 1225mm as per design.
Refractory Lining: Custom highalumina castables & insulating bricks (1700°C service temperature).
Internal Fittings (Cyclone Inlets): Abrasionresistant steel castings (Cr27).
Физик хэмжээсүүд: Tower heights from 80m to 120m; footprint tailored to plant layout constraints.
Байгаль орчны үйл ажиллагааны хүрээ: Designed for continuous operation with gas inlet temperatures up to 1150°C at the lowest cyclone stage.

6. ХЭРЭГЛЭЭНИЙ СУРТАЛЧИЛГАА

Capacity Expansion Retrofit Challenge A plant operating at 3,200 TPD needed to increase output by 25% without a new kiln. The existing preheater was a bottleneck.

Solution Engineering analysis led to a retrofit replacing the top two cyclone stages with our lowpressure drop designs and optimizing the calciner aerodynamics.

Results Achieved a sustained output of 4,000 TPD. The pressure drop reduction allowed the existing ID fan to handle increased gas flow without modification.

Alternative Fuel Integration Challenge A plant transitioning to higher rates of solid recovered fuel (SRF) experienced incomplete combustion and uneven calcination.

Solution Implementation of our multipoint burner array calciner system with dedicated SRF injection ports and enhanced mixing geometry.

Results Stable operation with >40% thermal substitution rate (TSR). Calcination degree at kiln inlet maintained consistently above 92%, improving kiln stability.

7. АРИЛЖААНЫ ХЭРЭГЛЭЭ

Үнийн шатлал: Projectbased quotation determined by capacity (TPD), нарийн төвөгтэй байдал (жишээ нь e., separateline vs inline calciner), материалын үзүүлэлтүүд, and scope of supply (full EPC vs equipment supply only).
Нэмэлт шинж чанарууд: Advanced process control interfaces, ceramic weld overlay on highwear ducts, comprehensive instrumentation packages including continuous temperature profiling.
Үйлчилгээний багцууд: Extended warranties on refractory linings; technical supervision during erection & ашиглалтанд оруулах; multiyear preventive maintenance agreements including thermal scanning services.
Санхүүжилтийн сонголтууд: Collaboration with export credit agencies; structured progressbased payment plans aligned with major manufacturing milestones; potential leasing arrangements through financial partners.

8. Түгээмэл асуултууд

1. How do you ensure compatibility with our existing rotary kiln?
A detailed process audit is conducted first—we analyze your current gas flows,temperatures,and material chemistry—to ensure seamless integration upstream from your existing rotary kiln connection point
2.Ердийн хүргэлтийн хугацаа гэж юу вэ?
For a complete tower system,the engineeringtoshipment timeline ranges from10to14months depending on capacity
3.Та гүйцэтгэлийн баталгаа өгдөг үү?
Yes we contractually guarantee key parameters including specific heat consumption capacity output,and system pressure drop based on agreedupon design conditions
4.How does this solution address NOx emissions?
The optimized multistage calciner design promotes staged combustion which inherently lowers NOx formation compared to conventional designs
5.What are the key spare parts recommendations?
A firstfill spares package focusing on highwear items like cyclone inlet castings thermocouples,and burner nozzles is provided with each project
6.Can you assist with dismantling old structures?
We can provide engineering support for safe demolition sequences as an optional service but typically do not perform physical dismantling
7.Are your designs compliant with international codes?
All structural designs conform to relevant standards including ASME Eurocodes or GB standards per client requirements