CHAENG slag grinding plant turnkey service

 1.Equipment Manufacture

Chaeng takes sole responsibility of all problems of grinding plant construction in EPC. Chaeng could select some main equipment basing on rich experience, so the

 mine design is in step with equipment manufacture, which greatly shortens the construction period, and saves time and cost for customers. In order to strictly control the period, Chaeng will formulate detailed and feasible project schedule in EPC, and project control group strictly supervise the progress of project. 

2.Installation & Commissioning

1)Installation & commission technology

Installation & commission is key link of raw material test, mine design, and equipment manufacture, and directly takes influence on production.

Installation and commission of grinding plant equipment is a very careful work with strong practicality. Any error may lead to low capacity which cannot reach the expectation. For example: in different construction, the same type of equipment would have deviation because of the opening location and installation etc. These differences will have a significant impact on the final production efficiency.

In view of the importance of installation and commission, Chaeng established professional installation company having four installation teams which are from the mine 

production line and led by engineering technicians who held the directors of grinding plant and mine leader. Installation personals Chaeng sent out participate in the whole mine design of clients, and there are two points for this: one is the old technicians are very familiar with structure, performance and using of Chaeng equipment; the other is the technician who can quickly solve many actual problems in plant construction understand the overall design of factory because of participating in the whole mine design.

2)Methods of Installation and Commission

For installation and commission, Chaeng upholds customer fist. There are 3 methods of installation and commission according to the actual situation of customers.

①Free guide of installation

Chaeng can send related technician to guide customer with the equipment installation and commissioning for saving customer's cost.The customer should responsible for the travel charge of the technician.

②Contract for materials

Chaeng arranges the installation and commission technicians, and clients prepare the components and instruments of installation of commission.

③Contract for labor and materials

Chaeng is responsible for tools, materials and personnel allocation of the installation and commission. Customers can directly wait for the final results.

3.Personnel Training

It is simultaneous for worker training and installation & commission in order to save time and cost. Worker training has two purposes, one is the grinding plant works earlier and produces benefit; the other is training technical team for customers to guarantee the normal operation of the factory in the future.

The technicians who have extremely rich practical experience for worker training are experts of installation and commission team. They help workers to pay attention to some details which usually don't be easy to notice but extremely important. These Chaeng technicians provide training from 3 aspects:

1.Operation training for all workers involved in mine grinding processing

2.Training for the common problems in the plant operation and processing technology; a live solution demonstration for workers

3.Training of operation experience grasping, the workers should operate machines by lots of exercises.

Through the above three aspects of training, workers could skillfully operate mine grinding technology (grinding particle size, adding burdening etc.) and processing equipment. Customers have their own technical team, which can prevent the dressing plant from long time stop.

When the training is completed, Chaeng Company will present free “Common faults handling of mining equipment”, “The operating procedures of processing plant” and common forms, which is convenient to manage operation of grinding plant.

CHAENG cement plant turnkey service Pre-sales Service

 Engineering Consulting

I Purpose of Engineering Consulting

Engineering consulting makes clients have a comprehensive understanding of the value of mine, the useful elements, available mineral processing technology, plant size, required equipment and period. 

II Contents of Engineering Consulting

Chaeng Technology Support Department is responsible for engineering consulting. When a client needs engineering consulting, firstly, Chaeng Research Institute will arrange an expert with rich dressing experienced to make sure the ore separability according to the analysis of mineral elements (Chaeng also makes this analysis). 

After making sure the ore separability, Technology Support Department would contact with mineral dressing construction departments including geology, mining, ore dressing, smelting, machinery, civil engineering, electric power to get a brief quotation.

Chaeng mine consulting provides services according to the need of clients.  The main contents of mines consulting include mining, mineral processing, external conditions, investment estimation and analysis of economic benefit.

III Results of Engineering Consulting

At last, engineering consult takes on economic benefits analysis for the customers including the cost analysis and profit estimate.  Mine costs include mining, transportation, mining beneficiation, financial management cost. Profit estimate includes ore grade, product, price, annual output, total income, total cost, profit before tax, comprehensive estimation (time of recovering the investment).

Raw Material Testing

Mineral dressing test is in charge of Mineral Dressing Research Institute belonging to Chaeng Company

I Preparation before test

The clients should provide about 50g representative samples, some special samples about 200~1000g. The simple test needs 30 working days, and the detailed test about half a year.

Sign the test contract with clients before the mineral dressing test, and make sure dressing process to test

II Testing process

1. Chemical Lab of Mineral Dressing Research Institute analyzes the material components (ore structure, mineral and types of ore) and chemical properties (elements, the particle size screening, density, ore relative grindability) of crude ore, and gets some data for the subsequent beneficiation test.

2. After the working of Chemical Lab, Mineral Dressing Research Room takes the mineral beneficiation test which tests the optimum conditions of dressing process. 

III Test results

After finishing all the tests, Mineral Dressing Lab writes a detailed “Mineral dressing test report” by summarizing the test process. In the last part of test report, the optimum technological process and technological parameters are presented.

Engineering Design

Three parts of mine design: feasibility study, preliminary design and construction plan

The key of mine design is all must be established on the basis of detailed investigation, and therefore Chaeng Mine Design Institute will firstly take a comprehensive field study to the mine of clients including the crude ore for dressing plant, site, water, electricity, traffic, geography, etc..

These investigation contents need the cooperation of geology, mining, ore dressing, smelting, machinery, civil engineering, electric power and other departments

I Feasibility study

In all the work of the working group to carry out, investigation, data collection and plan optimization is the most important basis for selecting plant construction scheme. For these important parts, working group requires different professional division and cooperation, including:

1, Geological specialty

2, Mining specialty

3, Mining machinery specialty

4, Civil engineering specialty 

5, Electric power specialty

6, Mineral dressing specialty

II Preliminary design

After "Feasibility study report" approved, Mine Design Institute starts preliminary design and comes up with the design of dressing plant construction. Design mainly involves: dressing, general layout, electric power, communication, civil engineering, environmental protection, water supply and drainage, tailing, safety and fire protection, investment estimates, economic benefit. For the improvement and extension enterprises, the preliminary design will illustrate the status, characteristics, plant, main problems, utilization of main buildings and equipment.

III Working drawings                                                         

When the preliminary design is approved, Mine Design Institute starts to design working drawings. Every aspect of dressing plant needs a lot of construction drawings (generally, over 100 working drawings), such as civil construction. Engineers of Chaeng Mining Institute are numerous with rich experience and drawing speed. When the working drawings completed, the designers must hand the drawings over to construction commanding officers, especially, the notes, strict regulation and important content.

Vertical roller mill innovations of Great Wall Machinery

September 4 to 5, the 11th G20 Summit will be held in Hangzhou, China. The theme of the summit is “build innovative, dynamic, linkage and inclusive world economy” and the summit lists “blueprint of economic growth by innovation” as a key issue for the first time.CHAENG (Great Wall Machinery) constantly extends product and industrial chains with the concept of technology and science first, especially paying attention to the development of high value-added and high-tech products with the feature of energy saving and emission reduction. Our company has won the important results in the fields of vertical roller mill, tube mill, rotary kiln, etc., forming the core competitiveness of company itself, which consolidates the foundation for our company to become the domestic first-class grinding system comprehensive service supplier.

Innovations of CHAENG

Technologies innovated by CHAENG obtain Utility model patent certificates issued by State Intellectual Property Office

A kind of feeding device applied in vertical roller mill (patent number: ZL 2015 2 0349738.9): effectively reduce the power consumption of belt conveyor transmission and civil engineering cost of system and allow vertical roller mill to run smoothly at the same time.

A kind of powder selecting device applied in vertical roller mill (patent number: ZL 2015 2 0349704.X): improve more than 15% of efficiency and reduce 5% of power consumption.

A kind of dismounting device for taper sleeve of grinding roller (patent number: ZL 2015 2 0349716.2): effectively improve the efficiency of dismounting taper sleeve of grinding roller and reduce dismounting cost.

φ4.2×13m double slide ball mill (patent number: ZL 2010 2 0285841.9):fundamentally solve the problem in like products that “cannot operate constantly because of overheat of sliding bearing at the discharge end”.

Innovation for intelligent control device of vertical roller mill

Intelligent control device of vertical roller mill allows the operator to perform statistical data of the equipment and operate at any time according to situations in the field, which is adaptable, easy to operate and reliable to use. It can ensure the smooth running of vertical roller mill. The device supports internet remote operation, human-computer interaction of which is accurate, convenient and reliable.

Design for the belt plate of rotary kiln

By reference to relevant technology and combined with production technology department, CHAENG replaces “floating plate” of rotary kiln by “replaceable plate”, which is convenient for manufacturing process and improving 20% of production efficiency. This design obtains users’ consistent high praise.

"Multi-purpose vertical roller mill"

Multi-purpose vertical roller mill with high efficiency and energy saving means that only one vertical roller mill can achieve the grinding of various materials (cement clinker, auxiliary material and slag particles admixture, etc.). This kind of vertical roller mill has been used in the yearly output of 1 million tons cement/ 0.6 million tons slag powder production line and operation effect has exceeded exceptions after 100 days’ operation.

In the future, CHAENG will continue to cooperate with design institute of building materials, colleges and universities and well-known building materials machinery experts to enhance the quality of the product through innovation and research and development to provide high value-added equipment for customers and give more value for the investment of customers!

Great Wall Machinery steel casting node cases

1. Project one: in 2014, the project of Shanghai Jinsha River Pedestrian Overcrossing orders 6 tons upper chord nodes with ZG20Mn5 material and intersection node with steel structure manufactured by our company is used in this project. In order to avoid the large stress of node caused by welding intersection and inconvenience of welding, cast-steel node is selected in the design, which requires material performance of cast-steel node should be equal to or better than Q420QD, wall thickness of cast-steel node should be no less than 40mm, and the minimum length of cast-steel bar should be no less than 1 meter.

However, all kinds of demanding requirements for Great Wal Machinery are the power to process high-class steel casting node. According to properties and technical requirements of Shanghai Jinsha River Pedestrian Overcrossing, Great Wal Machinery improves the casting technique of cast-steel node and finally manufactures the satisfactory cast-steel node for customers.

2. Project two: in 2013, Hangzhou Olympic Sports Center orders 55 tons steel-joining nodes from Great Wal Machinery. Design period of Hangzhou Olympic Sports Center is 100 years, belonging to the premium and large sports construction project. Awning with steel structure is lotus petal shape. There are many bars converging on the node between petals, the structure and force condition of which is complex. Single node has the features of large size, high strength of material and heavy weight. Thus, it need to find a large-scale foundry with advanced casting equipment and mature casting technology to be the supplier of node of the whole project. After careful comparison, construction party of Hangzhou Olympic Sports Center finally chooses Great Wal Machinery to manufacture all cast-steel nodes used in the project. On the one hand, Great Wal Machinery owns the domestic advanced testing equipment and inspection equipment, which can reach secondary inspection level; on the other hand, Great Wal Machinery has many successful cases in cast-steel node processing field to use for reference.

3. Project three: in 2011, Huai’an Stadium orders 4 tons arch springing steel nodes from Great Wal Machinery. Sculpt of Huai’an Stadium is novel, attractive and majestic, which is one of the few domestic large-span cable structure stadium. Because of novel structure, arch springing steel node of which adopts widely used cast-steel node at present, which has the high requirement for casting technology.

The application of cast-steel node produced by Great Wall Machinery in many buildings with steel structure also lays a foundation for this cooperation. This time, construction party of Huai’an Stadium comes to Great Wal Machinery to make an on-the-spot investigation and sign the cast-steel purchase contract with Great Wal Machinery immediately. According to the requirements of construction party of Huai’an Stadium, Great Wal Machinery makes the special treatment in the casting process of node with steel structure to ensure the quality of cast-steel node.

After the completion, with excellent design and reliable quality, Huai’an Stadium wins the 2012 annual “Jingang Award” and “2013 Gold Award of Construction Steel Structure of China (national prime-quality project)”, which proves that nodes manufactured by Great Wall Machinery meet the standards of national prime-quality project.

4. Project four: in 2011, Karamay regional digital network control center orders 5 tons nodes with steel structure from Great Wall Machinery. Because of Karamay located in Xinjiang, where is snow-prone area in China, buildings in this area must have the ability to withstand earthquake, snow and large temperature difference. As the core part in steel structure – node should have good mechanical property to ensure the stability of the whole steel structure.

At the beginning of construction of Karamay regional digital network control center, delegates of construction party comes to Great Wall Machinery to make an on-the-spot investigation, on the one hand for getting to know the strength of Great Wal Machinery, on the other hand for seeking for cooperation. Great Wal Machinery designs a set of feasible technical solution for matched cast-steel node of Karamay regional digital network control center and delegates of construction party is satisfied for that. Thus, large node product manufactured by Great Wall Machinery finally achieves the desired effect. To some extent, we can say that nodes produced by Great Wal Machinery improve the reliability and stability of the whole steel structure.

Progress of Indonesia annual output of 0.3 million tons nickel slag production line

It is reported that all equipment and parts have been shipped to Indonesia on May, 11, 2016 for annual output of 0.3 million tons nickel slag production line which CAHENG (Great Wall Machinery) will construct for Growth Steel Group. Currently, project design, civil engineering and equipment manufacturing has finished smoothly and equipment installation and debugging is coming to an end.

Project overview:

Because of the feature of energy saving and environmental protection of vertical roller mill manufactured by CHAENG, and after many times of visits, in November 2015, annual output of 0.3 million tons nickel slag production line contract is signed between Growth Steel Group and CHAENG.

Indonesia annual output of 0.3 million tons nickel slag production line is 2.0 updated version of CHAENG’s production line turnkey project and GRMS33.31 vertical roller millis used in this production line.

Process improving:

Figure: Drawing of installed dust collector

Vertical roller mill manufactured by CHAENG sets crushing, drying, grinding, powder selecting and transporting in one with the advantages of high grinding efficiency, strong drying ability, easy to adjust product fineness, low noise, low electricity consumption, simple technological process, little wear, freight cost saving, etc. CHAENG has been the leader in the field, while we are not content with this and our technicians take dust treatment for the whole system and adopt closed production method from windrow to finished product, which on the one hand can eliminate most of the dust to achieve the purpose of dust collecting and environmental protection; on the other hand maximize the value-added service of new system.

Environmental protection design：

Figure: Drawing of installed blue vertical roller mill

The color of the equipment manufactured by CHAENG is gray previously, showing a majestic momentum. However, with the adjustment and change of industrial structure, the requirement of environmental protection occupies a greater voice in industrial field. CHAENG makes a great adjustment this time: the main color of the equipment is lake blue, supplemented by the corresponding light blue and white. The three colors run through the whole production line. New color will highlight highlights and reflect the requirement of environmental protection, which shows the improvement of CHAENG’s technology and resolution to respond the national environmental protection requirement.

The completion of Indonesia nickel slag production line marks that export of turnkey production line project of CHAENG has a good beginning and to some extent, it provides an opportunity for CHAENG and Growth Steel Group to smoothly start international cooperation on slag recycling project at the same time.

How much do you invest in the equipment of slag powder production line?

CHAENG (Great Wall Machinery) is the world-class grinding system integrated service supplier, specially providing the “turnkey” service of daily output of 20-120 tons of slag powder production line, steel slag powder production line and nickel slag powder production line for customers in china and abroad. Currently, CHAENG has own more than 100 projects of slag powder/ steel slag powder/ nickel slag powder production line worldwide including Growth Steel Group, Hebei Aosen Group, Shanghai Baosteel Group, Henan Mengdian Group, etc. Great Wall Machinery has been the leading brand of GGBS turnkey project!

How does CHAENG expand the market step by step? For this question, we must mention that in order to popularize slag powder production line, CHAENG invests RMB 50 million in 2010 and constructs a yearly output of 0.6 million tons slag powder production line by itself.

The showcase production line of CHAENG produces 0.6 million tons slag powder yearly, main product of which is S95 slag powder. GRMS46.41 slag vertical roller millmanufactured by great wall machinery is used in this production line, which introduces the technology of Tianjin Design Institute, adopts international advanced and proven vertical mill process integrating drying, grinding and powder selecting and applies DCS remote central control system equipped with efficient and energy-saving dust collector and equipment. Dust content in stack gas is lower than that of national emission standard and process technology and equipment has reached the international advanced level.

How much do you need to invest a slag powder production line? Please click and consult online customer service on the right side.

Well, how does the quality of slag powder produced by the slag powder production line of CHAENG?

According to the head of CHAENG, slag powder is mainly used to be blended with cement and concrete to enhance the long-term strength of cement and concrete and improve the appearance of concrete, making it smooth and high brightness. It realizes the recycling and value-added exploitation of smelting waste of iron and steel enterprises and no longer consumes new resources, which is a green environmental new type building material product.

Pouring quantity of concrete of construction in process which GGBS manufactured by CHAENG and used to is accumulated up to 0.03 million cubic meters.

Clinker production stage in cement production line

Clinker production is the most energy intensive stage in cement production line, accounting for over 90% of total industry energy use, and virtually all of the fuel use. Clinker is produced by pyroprocessing in a large rotary kilns. These rotary kiln systems evaporate the inherent water in the raw meal, calcine the carbonate onstituents , and form cement minerals . any different fuels can be used in the rotary kiln. In these rotary kilns a tube with a diameter up to 8 meters (25 feet) is installed at a 3-4 degree angle that rotates 1-3 times per minute. The ground raw material, fed into the top of the kiln, moves down the tube counter current to the flow of gases and toward the flame-end of the rotary kiln, where the raw meal is dried, calcined, and enters into the sintering zone. In the clinkering zone, the combustion gas reaches a temperature of 1800-2000°C (3300–3600 °F). While In a wet rotary kiln, the raw meal typically contains approximately 36% moisture. These kilns were developed as an upgrade of the original long dry kiln to improve the chemical uniformity in the raw meal. The water is first evaporated in the rotary kiln in the low temperature zone. The evaporation step makes a long kiln necessary. The length to diameter ratio may be up to 38, with lengths up to 230 meters (252 yards). The capacity of large units may be up to 3600 tonnes (3970 short tons) of clinker per day. Fuel use in a wet kiln can vary between 5.3 an G In a dryrotary kiln, feed material with much lower moisture content (0.5%) is used, thereby reducing the need for evaporation and reducing kiln length. The first development of the dry process took place in the U.S. and was a long dry kiln without preheating . Later developments have added multi-stage suspension preheaters or shaft preheater. Pre-calciner technology was more recently developed in which a second combustion chamber has been added between the kiln and a conventional pre-heater that allows for further reduction of kiln fuel requirements. The typical fuel consumption of a dry kiln with 4 or 5-stage preheating can vary between 3.2 and 3.5 GJ/tonne clinker, electricity use increases slightly due to the increased pressure drop across the system. A six stage preheater kiln can theoretically use as low as 2.9-3.0 GJ/tonne clinker. The most efficient preheater, pre-calciner kilns use approximately 2.9 GJ/tonne clinker.

Once the clinker is formed in the rotary kiln, it is cooled rapidly to minimize the formation of a glass phase and ensure the maximum yield of alite formation, an important component for the hardening properties of cement. The main cooling technologies are either the grate cooler or the tube or planetary cooler. In the grate cooler, the clinker is transported over a reciprocating grate through which air flows perpendicular to the flow of clinker. In the planetary cooler (a series of tubes surrounding the discharge end of the rotary kiln),the clinker is cooled in a counter-current air stream. The cooling air is used as secondary combustion air for the rotary kiln.