1.5 Million t/a GGBS Plant of Baosteel Group Corporation

I. Project Overview

1.5 Million t/a GGBS Plant of Baosteel Group Corporation

1. Project Company:

 Ningbo Steel Co., Ltd.

2. Project Location:

Ningbo City, Zhejiang Province, China

3. Main Equipment:

GRMS46.41*2 Vertical Roller Mill

4. Production Ability:

1.5 Millon tons GGBS

It is a two-purpose Production Line with two parts. One is a steel slag production line with annual capacity of 300,000 million tons slag powder, and the other one is a GGBFS production line with annum capacity of 1.2 million tons GGBFS. The main grinding equipment is designed with 2 GRMS vertical roller mills and 1 steel slag ball mill. All of the technical operation can be controlled in DCS Room, which is the most advanced level technology in the world. Baosteel visited us for the A check in April, 2014. All the device and equipment including vertical mill, electric cabinet, accessories, etc. are all qualified as they required.

II. Project Configurations

Equipment	Specification	Blaine Finess
GRMS46.41	Power consumption system: 38kWh/t Capacity: 105 t/h Number of rollers: 4	4200~4500 cm²/g
Steel Slag Ball Mill	φ3.2x13m  Capacity: 50t/h	4500-5000 cm²/g

 III. Project Analysis

1. The project is a composite powder line with the maximum productivity and best equipment that Baosteel ever invested at present. It is an effective study on the reuse of industry waste discharged from steel plant. It also will be a national demonstration GGBFS Plant as soon as being put into use next year.

2. GRMS46.41 is known as the heart of this production line. It helps reduce power consumption by 20%- 30%. The GGBFS Braine Test can at 4200-4500cm²/g, which definitely meets customer’s particle fineness and size distribution requirements. They are ideal admixtures for a variety of Portland cements.

3. The steel slag grinding is combined with the process of iron removal from outside loop, which can pick out 1.5% ferruginous matters from steel slag tailings. The granulated steel slags thus can be in a very fine condition. The Braine test of the finished products is over 4500-5000cm2/g. The qualified activity is the best admixture option for the cement blending material and concrete.

4. off-Gas Emission and Noise Level Meet National Standards

Measures are taken to make certain that our production line meets the GB4915-2004 standards for dust emission and GB12348-2008 standards for noise control. The purpose of our effort is to ensure the emission of any environmental pollutants meets related national standards and its impact on the surroundings would be reduced to minimum.

5. Low Electricity Consumption

Innovations in techniques allow us to produce an energy-efficient vertical roller mill that can effectively crush the glass structure of the slag between layers. It usually takes ≤43KWh/ton to get the finished products of 4200-4500cm2/g, which is much lower than the average level in this industry and greatly helps save production cost.

Ground Granulated Blast Furnace Slag (GGBS) Production Line

Granulated Blast Furnace Slag is obtained by rapidly chilling (quenching) the molten ash from the furnace with the help of water. During this process, the slag gets fragmented and transformed into amorphous granules , The granulated slag is ground to desired fineness for producing GGBS.

The chemical composition of CHAENG’s GGBS contributes to the production of superior cement. Over the period of time, its load-bearing properties continue to increase as it absorbs surplus lime released during hydration to form more calcium silicate hydrates. These hydrates add to the strength of the cement.

The multi-fold advantages of GGBS when used with cement

Ensures higher durability of structure.

Reduces the temperature rise and helps to avoid early-age thermal cracking.

Improved workability.

It is off-white in colour and substantially lighter than cement . Resultantly it helps soften the visual impact of large structures such as bridges and retaining walls.

Where GGBS can be used?

GGBS significant attribute of providing ultimate strength when added to Portland cement makes it the preferred material in the construction of;

High-rise buildings.

Marine applications such as dams, shore protection construction.

Effluent and sewage treatment plants.

Cement products such as tiles, pipes, blocks, etc.

The vertical roller mill has been widely used and promoted in the electric power, metallurgy, chemical industry, non-metal industry because the overall efficiency attributed to energy-saving and low consumption is becoming more and more evident in the cement industry.GGBS vertical roller mill is the equipment to grind Ground Granulated Blast furnace Slag (GGBS)，Nickel slag, manganese slag and so on into small particles.CHAENG is professional cement equipment manufacture , we 50 years of development history , we can provide provide professional cement equipment , include vertical roller mill,ball mill, rotary kiln ,and a complete GGBS plant . If you want to know more about our product our product , please live a messager to us.

slag vertical grinding machine how to stable material bed and increase capacity

CHAENG ( Great Wall Machinery ) cement vertical mill,  slag vertical grinding machine in many grinding cement clinker, cement case, the operating results have been satisfactory. As customer demand for vertical mill grinding diversity, "a multi-purpose mill" will become increasingly popular, however, on the market a lot of versatility vertical mill - that can be achieved simultaneously slag grinding, mixing materials, cement and other material, sometimes not as good as some unsatisfactory issues, such as: the grinding roller normal wear and tear,vertical roller mill production capacity is low, high power consumption, will play a crucial role in stabilizing the mill if you can make a better material layer down .

CHAENG mechanical engineers to introduce, on the stability of the bed has a lot of measures, now share two:

First, make no segregation blanking

We know the requirements of material compaction roller press, no segregation, the same, the same vertical mill needs no segregation of materials and natural compaction during Grinding Table movement of the center to the edge.

Second, set up the material bed plus the compaction roller may play a role

For slag and cement grinding, Loesche first proposed the main rollers + auxiliary roll stabilizing material layer method, namely auxiliary roller compacted material bed, the main roller mill, the timber for mixing, this dry clinker material, provided auxiliary roller compacted material bed may be more important.

Therefore, in the vertical mill set up a simple roller compacted material to Jane, of course, you want to calculate, choose express good roll Jane dimension, but also in the drum arranged above plus better wear lug engaging material , giving it a predetermined speed of rotation, as well as for different materials, different thickness of material required to set the material layer can be adjusted means.

Through the above two measures, in the clinker grinding and mixing materials, will be able to get better material layer, together with a suitable mill temperature, suitable loading pressure, and a suitable blanking tube height.

CHAENG is the domestic first-class mechanical grinding systems integration services, to provide customers with first-class large vertical mill, cement vertical mill, slag vertical mill equipment, which provides the "One vertical mill, eight service" popular value-added services customers, CHAENG brand is your best choice.

Uzbekistan customer officially signed a cement production line of 1000TPD with CHAENG

Due to the central Asian region is under the influence of "One Belt and One Road" policy, they started to develop the infrastructure construction, will undoubtedly increase the demand for cement. After a multinational investigation contrast, Uzbekistan customer officially signed a cement production line of 1000TPD with CHAENG (Xinxiang Great Wall Machinery) on March 16, 2016.

This cooperation only lasted for less than 10 days from investigation to sign the contract. It’s the technical strength and good reputation in the industry of CHAENG to let customer to make a firm choice. It marks that CHAENG achieves new breakthrough on exploiting central Asia market again.

Project Advantages

For the new type cement production line, Chaeng adopts the advanced energy saving technology in the crushing and calcining process, the waste hot air generated from the rotary kiln can be recycled for raw material drying and pre-heat pyrolysing to achieve the energy saving , environmental friendly purpose.

Powerful crushing,scientific stockpiling

The limestone crushing use single-section hammer crusher that feeding size is 800mm, production capacity is 180 t/h, and grinding by advanced vertical raw mill- GRMR22.31. Scientific material piling and taking technology, to achieve the initial raw material homogenization.

New vertical mill grinding process, Low energy consumption in grinding

The energy consumption in cement grinding process accounts for more than 60% of the whole production line, therefore, it has great significance in ensuring product quality and reducing energy consumption by using high efficiency and energy saving GRM series vertical roller mill to deal with raw material, coal, clinker.

Preheating before calcination , High efficiency and energy saving

Raw materials are sent into φ3.2x50m rotary kiln to be calcined after preheating and precalcining in the cyclone preheater . That is conducive to improve the production efficiency of kiln system, shorten rotary kiln length, and reduce the heat consumption of clinker calcining.

Low Investment ,Environment Friendly

Vertical mill grinding system operate in negative pressure, low dust pollution; System equipment layout is compact, low area occupying, low investment in civil construction; Environmental protection in recycling kiln exhaust gas.

Study on grinding process

It has been the consensus that vertical mill has advantages in the cement production, especially in the clinker grinding stage from the survey. Vertical mill has the feature of low electricity consumption, high production capacity, high cement quality, thus, it is the trend that vertical mill replace the ball mill.

Since the first ball mill produced in 1968, the company has produced more than 2600 sets of mills and rotary kilns in various specifications, and the products are sold to each provinces of China, and exported to America, Russia, Japan, Brazil, India, South Korea, Vietnam, Kenya, Iran and others, enjoys high market reputation.

blast furnace slag production line

Annual Output : 20 tons --1.5 million tons

Application Equipment : GRMS slag vertical mill

Grinding materials : blast furnace slag,Steel slag,nickel slag,Manganese slag

Equipment matching : Belt feed+Vibrating screen+slag vertical mill+hot blast stove+dust collector+warehouse

As the important equivalent substitutes for cement production,GGBFS can not only significantly improve the overall performance of cement and concrete, but also significantly reduce the production cost. Now it has been widely used in cement plant, grinding station and steel factories as a new kind of high effectively admixtures. For this situation, we may say: "who first invests will first benefits."

CHAENG (Great Wall Machinery) can undertake 20 tons --1.5 million tons of Blast furnace slag/Steel slag/Nickel slag/Manganese slag powder production EPC projects. Up to now, CHAENG has constructed more than 100 slag grinding production lines at home and abroad.

Process Description

The stacked slag is packed and feed by the forklift trucks, then transported by belt conveyor. During transmission, the slag will pass through the iron separator and vibrating screen, then through the weighing equipment and elevator, finally come into the vertical roller mill. With the hot air form cowper stove, the slag after grinding, will come through the separator, while drying. Slag meets the fineness requirement will pass through the separator, then delivered by air blower and elevator, finally come to the storage silo.

Energy-saving, environment friendly, simple process, high intelligence

Nowadays, the slag vertical roller mills are widely accepted by customers, but some customers may still doubt about the vertical roller mill and ball mill. By doing research in more than 10 customers factory, we have summed up these difference between this two kinds of mills.

Investment return

Slag grinding line investment returns analysis

Take our 600,000 t/a slag power production line as an example, the total investment of this project is RMB 50 million. It took into production on April, 2011. Within 2 years, all the investments has returned and now is benefits. The investment details list as below:

Project	index	actual motion
commissioning date	commissioning date	april,2011
investment calculations	total investment	50million
cost account	cost of raw material	70 yuan/t
	Production costs (including wages, electricity, coal, maintenance fees, cost of sales, etc.)	50 yuan
profit calculation	Price	160 yuan/t
	profit per ton	30 yuan/t
	annual profit	30*60million=1800million
economic benefit	2 years and 10 months recycling all investment (now in a state of pure profit)
The quality of slag powder	Specific surface area	430 m3/kg
	7 d activity index	Can reach 100%
	activity index	Achieve GGBS national standard S95 level above
Product Sales	Product sales region	Product sales in xinxiang, shangqiu, xuchang, etc

Product advantages

1. The introduction of the German Loesche vertical mill technology, process system simple.

2. equipment operation rate, energy saving and environmental protection.

3. the system is easy to operate, save a lot of labor costs.

4. the latter parts replacement is simple and convenient

Technical Parameters

Equipment selection recommendations:

CHAENG already has more than more than 100 customers recently, among them, the capacity of 1 million t/a, 600,000 t/a and 300,000 t/a has occupied more than 80%. Below sheet has show the main equipment specs and parameters of these three capacities.

Product Specificationsct	GRMS53.41	GRMS46.41GRM4	RGRMS33.31MS.31
Annual production(tons)	1,000,000	600,000	300,000
Designed production(t/h)	150	90	45
Raw materials input amount(t/h)	188	125	65
Actual output(t/h)	160	105	55
Final products fineness(m2/Kg)	500	500	500
Power consumption (KWh/t)	26.5	28.5	30
System power consumption(KWh/t)	35	37	42
Coal consumption (equivalent to standard coal)(kg)	17	18	18
Metal recovery of per ton slag(%)	0.2-0.3	0.2-0.3	0.2-0.3

Service support

In order to ensure customers'projects are carried out and completed successfully, Great Wall Machinery has brought out the " A vertical mill with eight services" and provide the guidance during the total project, from early start to final products.

CHAENG (Great Wall Machinery) GGBS Plant with 600,000 t/a Capacity

I. Project Overview

1. Project Company:

Great Wall Slag Powder Co., Ltd.

2. Project Location:

Huixian City, Henan Province, China

3. Main Equipment:

GRMS46.41 Slag Vertical Roller Mill

4. Production Ability:

600,000 tons GGBFS

II. Project Configurations

In 2009, we invested CNY 50 million to build the GGBFS plant demonstration and training base with capacity 600,000 t/a, the main equipment of which used the biggest self-made GRMS 46.41 vertical mill. The purpose of this plant is to let customer have a direct knowledge on GGBFS process and technology. After running 3 years, the project has recovered total cost of investment.

1. Magnetic Separators

A magnetic separator creates strong magnetic attractions with ferrous materials. It is commonly used to remove unwanted iron contaminants from cement mixtures as they are conveyed on a belt conveyor to the crusher and grinding mill. Separating iron from mixtures avoids the risk of long, big iron parts tearing open the conveyor belt, ensures the proper functioning of the crusher and grinder, and improves the grade of raw material. In addition, recovering ferrous metals from raw materials also comes with financial benefits.

Our permanent magnet separator for pipeline is an automatic high-performing magnetic separation device. It is often utilized in cement, electricity, ceramics, bricks and tiles, chemical engineering, food, glass, metallurgy, and steel industries, as a separator of choice when it comes to purifying materials and ensuring the operational safety of the downstream equipment on the production line.

2. Dust Collectors

Air-borne powder enters the rotary separator at its bottom, where guide vanes force the air to change from an upward flow to a tangential flow. The separator rotor tends to rotate along with the air flow without causing any drag to the stream. Hence, a centrifugal zone is formed between the guide vanes and separator vanes, where powder is separated from air.

During separation, larger particles are thrown outward by rotary force of the separator rotor, falling to the bottom of separator due to the force of gravity. After exiting the centrifugal zone, these oversize particles are collected in a conical hopper and returned to the roller mill for further grinding. Finer particles are brought through the center of the separator chamber and out the top, where they are collected by a dust collector.

3. Central Control System

The central control system is a critical part of the production line. It is comprised of the Distributed Control System, and the Closed-Circuit Television which contains 6 monitor circuits.

In a distributed control system, or DCS for short, there are a number of computers, each controlling a separate circuit. Information from each computer can be collected together and obtained by the central controller, which facilitates centralized management and control. Compared with the computer controlled multilevel system, DCS has the advantages of optimized, flexible layout, low cost, high reliability, maximum accessibility, great flexibility, easy maintenance, good compatibility, and comprehensive functionalities.

The closed-circuit television, or CCTV, records images of different production sites, stores them in a hard drive, and sends real-time information to the control center. Authorized staff can view the present state of each production site. In case of emergency, they are able to send men to the site. This prevents potential severe accidents from occurring. Typical functions of CCTV include the following.

Multiple monitor circuits

Video recording

Video search

Video replay

Pan control

Camera lens control

III. Project Analysis

Since the production line went into operation, GGBFS sales increased constantly, and achieved excellent economic benefit. After running 3 years, the project has recovered all investment cost, and began to profit steady. Besides, the greater values of the project purpose on the demonstration effect when customers come to visit, meanwhile it enhances customer’s confidence to the quality of our product and ability of turnkey project, and play an important role in our orders.

1.5 Million t/a GGBS Plant of Baosteel Group Corporation

I. Project Overview

1.5 Million t/a GGBS Plant of Baosteel Group Corporation

1. Project Company:

 Ningbo Steel Co., Ltd.

2. Project Location:

Ningbo City, Zhejiang Province, China

3. Main Equipment:

GRMS46.41*2 Vertical Roller Mill

4. Production Ability:

1.5 Millon tons GGBS

It is a two-purpose Production Line with two parts. One is a steel slag production line with annual capacity of 300,000 million tons slag powder, and the other one is a GGBFS production line with annum capacity of 1.2 million tons GGBFS. The main grinding equipment is designed with 2 GRMS vertical roller mills and 1 steel slag ball mill. All of the technical operation can be controlled in DCS Room, which is the most advanced level technology in the world. Baosteel visited us for the A check in April, 2014. All the device and equipment including vertical mill, electric cabinet, accessories, etc. are all qualified as they required.

II. Project Configurations

Equipment	Specification	Blaine Finess
GRMS46.41	Power consumption system: 38kWh/t Capacity: 105 t/h Number of rollers: 4	4200~4500 cm²/g
Steel Slag Ball Mill	φ3.2x13m  Capacity: 50t/h	4500-5000 cm²/g

 III. Project Analysis

1. The project is a composite powder line with the maximum productivity and best equipment that Baosteel ever invested at present. It is an effective study on the reuse of industry waste discharged from steel plant. It also will be a national demonstration GGBFS Plant as soon as being put into use next year.

2. GRMS46.41 is known as the heart of this production line. It helps reduce power consumption by 20%- 30%. The GGBFS Braine Test can at 4200-4500cm²/g, which definitely meets customer’s particle fineness and size distribution requirements. They are ideal admixtures for a variety of Portland cements.

3. The steel slag grinding is combined with the process of iron removal from outside loop, which can pick out 1.5% ferruginous matters from steel slag tailings. The granulated steel slags thus can be in a very fine condition. The Braine test of the finished products is over 4500-5000cm2/g. The qualified activity is the best admixture option for the cement blending material and concrete.

4. off-Gas Emission and Noise Level Meet National Standards

Measures are taken to make certain that our production line meets the GB4915-2004 standards for dust emission and GB12348-2008 standards for noise control. The purpose of our effort is to ensure the emission of any environmental pollutants meets related national standards and its impact on the surroundings would be reduced to minimum.

5. Low Electricity Consumption

Innovations in techniques allow us to produce an energy-efficient vertical roller mill that can effectively crush the glass structure of the slag between layers. It usually takes ≤43KWh/ton to get the finished products of 4200-4500cm2/g, which is much lower than the average level in this industry and greatly helps save production cost.