(S Plant Technical Report with German-Japanese Methods)
Process Innovation Highlights
S セメント工場‘s closed-circuit grinding system achieves industry-leading performance through:
CKP-170 vertical mill + φ3.9m×12m dual-chamber ball mill synergy
95% material ≤10mm after CKP pre-grinding
Cyclone separator と 260% circulation load rate
Key Performance Metrics
| Parameter | Result | Industry Benchmark |
|---|---|---|
| Power Consumption | 39 kWh/t | 42-45 kWh/t |
| 28-Day Strength | 52 MPa | 48-50 MPa |
| Quality Stability | 32μm residue ±0.5% | ±2% variation |
Precision Quality Control Technology
1. German Negative Pressure Sieve Advantages
私たちの DIN 66165-compliant sieve system outperforms laser analyzers for routine QC:
Speed:
32μm test: 8-10 minutes (vs 25+ minutes for laser)
45μm test: 4-6 minutes と <0.5% error margin
信頼性:
Zero clogging with 70mm sieve diameter design
1g sample size ensures representative testing
Technical Note: Laser analyzers show 15-18% higher sub-10μm readings due to particle agglomeration.
2. Why 32μm Residue is Critical
When 32μm residue exceeded 16-20% control range:
28-day strength decreased by 4MPa
80μm residue remained unchanged at 0.2-0.4%
Particle distribution shifted +12% in 3-10μm range
Optimization Techniques
1.Grinding Aid Application
0.02-0.03% dosage optimizes:
Particle distribution (reduces over-grinding below 3μm)
Mill throughput (+8% capacity observed)
2.Separator Efficiency Management
Maintain 60% separation efficiency
Control return material ≤10mm at 95% rate
3.Particle Distribution Control
32μm + 45μm residue dual monitoring
Hourly Blaine tests for correlation verification
Technical Achievements
P.O 42.5R Cement Properties:
Initial setting time: 45-55 minutes
3-day compressive strength: 28±0.5 MPa
28-day strength consistency: ±1.2 MPa
System Reliability:
12,000+ operating hours without major maintenance
<0.1% production downtime due to QC issues
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