Cement plants have complex production processes, from raw material crushing and clinker calcination to finished product packaging. Each process has very different requirements for belt conveyors.
Cement plants work in harsh conditions: high temperature, heavy dust, strong abrasion, and lots of powder. Choosing the right heavy-duty belt conveyor keeps production stable and cuts maintenance costs.
1. Start Here: Match Your Process and Material
You cannot use the same conveyor for every job. First, match the conveyor to your process and material.
- Raw material handling: limestone, clay, iron powder.Features: large lumps, heavy, highly abrasive.Recommend: general heavy-duty belt conveyor with herringbone belt.
- Clinker handling: high-temperature clinker.Features: 150–200°C, high hardness, very abrasive.Recommend: heat-resistant heavy-duty belt conveyor.
- Powder handling: raw meal, cement powder, fly ash.Features: flows easily, creates dust, sticks easily.Recommend: fully sealed belt conveyor or steep-angle sidewall belt conveyor.
- Finished product dispatch: bagged or bulk cement.Features: needs cleanliness, prevents breakage.Recommend: light anti-slip belt conveyor or pipe belt conveyor.
2. Three Key Parameters
After you choose the type, calculate these three critical values.
(1) Capacity
Match the capacity to your kiln output.
- Small plants (≤2000 t/d): belt width 800–1000 mm.
- Large plants (≥2500 t/d): belt width 1200–1600 mm.
(2) Speed
Control speed to protect materials and improve efficiency.
- Powder and clinker: slow down to 1.2–1.6 m/s. Fast speed causes heavy dust and belt damage.
- Lumpy limestone: speed up to 1.8–2.5 m/s for higher efficiency.
(3) Incline Angle
Follow the material’s angle of repose.
- Normal lumpy material: max angle 18–22°.
- Hot clinker: keep angle below 16°.
- Limited space: use steep-angle sidewall conveyor. It can lift at 30–90° and saves space.
3. Adapt to Cement Plant Conditions
Cement plants demand three special designs: heat resistance, wear resistance, and dust control.
(1) Heat Resistance (for clinker)
- Use heat-resistant belt that withstands at least 200°C.
- Install heat-resistant bearings and high-temperature grease.
(2) Wear Resistance (for raw materials)
- Use thick-wall or wear-resistant idlers.
- Add ceramic liners inside the chute.
(3) Dust Control (for powder)
- Use fully sealed covers.
- Add dust removal ports to connect with your central dust system.
4. Safety and Easy Maintenance
Cement plants run 24/7. Downtime is very costly.
Safety devices you need:
- Anti-run-off switches
- Emergency stop cables
- Speed sensors
- Anti-rollback devices for inclined conveyors
Maintenance tips:
- Use easy-to-replace idlers.
- Choose standard parts to lower costs.
5. Special Applications
- Long-distance transport: use heavy-duty conveyor with multiple drives and automatic tensioning.
- Multiple loading / unloading points: use movable or reversible conveyor.
- Strict environmental rules: use pipe belt conveyor for zero dust leakage.
6. FAQ
Q1: What is the most important first step?
A1: First, analyze your material in detail. Record particle size, density, temperature, moisture, and abrasiveness. These data decide every part of your conveyor. Wrong data leads to insufficient capacity or wasted investment.
Q2: How hot can a heat-resistant belt work? How long does it last?
A2: A good heat-resistant belt can handle short-time 200–250°C. But high heat shortens belt life. At over 150°C, the belt may last only 1/2 or 1/3 of normal life. Use heat-resistant parts and add cooling sections.
Q3: What is special about long-distance conveyors?
- Use multiple drive units.
- Use automatic tensioning system.
- Use steel cord belts.
- Install full-line monitoring for safety.
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