Building a small cement plant with a daily output of 40 tons requires comprehensive consideration of technology, equipment, environmental protection, capital and market factors. The following is a step-by-step guide to help you plan the construction process:
Preliminary preparation for a small cement plant
• Determine the demand and competitor situation in the target market (local or surrounding areas).
• Analyze the supply source and cost of raw materials (limestone, clay, gypsum, coal, etc.).
• Assess whether local policies (environmental protection, taxation, land approval) support it.
Site selection requirements for small cement plants
• Close to the raw material production area to reduce transportation costs.
• Convenient transportation (road/railway) to facilitate the transportation of finished products.
• Ensure a stable power supply (cement production consumes a lot of electricity).
• Industrial land that meets environmental protection requirements (far away from residential areas).
Budget for small cement plants
• Equipment investment: about 2-5 million yuan (depending on the degree of automation).
• Land and plant: about 500,000-1 million yuan.
• Environmental protection facilities: 500,000-1 million yuan.
• Working capital: 500,000-1,000,000 yuan.
Process flow and equipment selection of small cement plants
1. Main production process
• Raw material crushing: Limestone, clay and other raw materials are crushed to a suitable particle size by a crusher.
• Pre-homogenization: The raw materials are mixed evenly.
• Grinding: The raw material mill (ball mill or vertical mill) grinds the raw materials into raw material powder.
• Calcination: The raw material is calcined at high temperature in a vertical kiln or a small rotary kiln to produce clinker (core link).
• Cooling and mixing: After the clinker is cooled, it is mixed with gypsum, slag, etc.
• Cement grinding: Grind it into finished products through a cement mill.
• Packaging and storage: Bags or bulk are shipped out of the factory.
2. List of key equipment
• Crusher: Jaw crusher or hammer crusher.
• Raw material mill: small ball mill or vertical mill (vertical mill is more energy-efficient).
• Calcination equipment: It is recommended to choose a mechanized vertical kiln (low investment, suitable for small scale). If the budget is sufficient, a small rotary kiln (higher efficiency) can be selected.
• Cement mill: small ball mills such as Φ1.5×5.7m.
• Dust removal equipment: bag dust collector, electrostatic dust collector.
• Packaging machine: semi-automatic or fully automatic packaging line.
Environmental protection and energy-saving measures for small cement plants
• Dust control:
All dust-generating points (crushing, grinding, packaging) are equipped with dust removal equipment.
Close the conveyor belt and silo to reduce dust spillage.
• Waste gas treatment:
Desulfurization and denitrification equipment is configured in the calcination process (in compliance with national emission standards).
• Noise control:
The equipment is equipped with a soundproof cover, and the factory building uses sound insulation materials.
• Resource recycling:
Waste heat recovery (rotary kiln waste heat can be used for power generation or drying raw materials).
Industrial waste residues such as slag and fly ash can be used as mixed materials.
Suggestions for the construction and operation of small cement plants
• Phased investment:
In the initial stage, the core production line (calcination + grinding) can be built first, and then the automation equipment can be gradually added.
• Staffing:
Technical workers (kiln operators, mechanics) need to undergo professional training.
Managers need to be familiar with cement production processes and safety management.
• Quality control:
Establish a laboratory to regularly test the chemical composition and physical properties of raw materials, clinker, and finished products.
• Sales channels:
Cooperate with local construction companies and building materials dealers to sign long-term supply agreements.
Provide bulk cement services (lower cost).
The construction of a small cement plant with a daily output of 40 tons should be based on low cost, high environmental protection, and flexible operation. It is recommended to give priority to mature small equipment solutions, strictly control pollution emissions, and deepen the local market. In the initial stage, a professional team can be hired to carry out process design to avoid the risk of production suspension due to technical errors.
