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The new 3000 t/d dry-process production line
at the OOO Sengilejewskij cement plant

E. Shchegolyaev, KHD Humboldt Wedag, Moscow, Russia


The commissioning of a modern, dry-process, production line with a planned clinker output of 3000 t/d was celebrated at the OOO Sengilejewskij cement plant in the Russian town of Sengilej in the Uljanowsk region in July 2015. The history of the cement plant belonging to the Eurocement Group goes back to the beginning of the last century. It was previously equipped with wet-process kilns. Chalk with an average as-dug moisture content of 20 % is used as the main raw material, so during the planning use was made of the proven raw material processing technology used at OAO Mordowzement. The raw material mix is dried with the exhaust gases from the 4-stage cyclone preheater and a gas-turbine power station and ground to a fineness of ≤ 15 % residue on 90 µm in an MPS 4250 B roller grinding mill from Gebr. Pfeiffer SE, Kaiserslautern. The homogenized raw meal is then fed into the cyclone preheater with up-stream PYROCLON-R calciner. The clinker is burnt in the 4.4 m diameter x 52.0 m rotary kiln on three support stations and then cooled in a PYROFLOOR cooler working on the “Walking Floor” principle. The cement is ground in two dual-chamber ball mills that each has a drive with an installed rating of 4 000 kW and operates in closed circuit with a high-performance separator to produce CEM I 42,5 R and CEM IV/ A 32,5 N cements. The cement is bagged with an 8 RSE rotary packer or is dispatched as bulk cement by road or in ships on the nearby Volga. The process stages in the cement plant are monitored and controlled from a modern control room. The process engineering design of the new production line was carried out mainly by ZAB Zement­anlagenbau GmbH Dessau, a subsidiary of KHD Humboldt Wedag International AG. The basic engineering, the supply of the production equipment, the installation and commissioning and the training of the personnel were carried out in close cooperation between KHD in Cologne and its subsid­iary in Dessau. The preliminary engineering was handled by OOO Giprozement in St Petersburg, and the implementation project was the responsibility of OAO Sibniiprojektzement in Novosibirsk.


Summary CEMENT INTERNATIONAL 04/2016 pp 46-51

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04/2016 Content:

The new 3000 t/d dry-process production line at the OOO Sengilejewskij cement plant

Detailed calculation of the grinding and classifying processes in a vertical roller mill by coupled hybrid modelling

Large gear unit repair on a two-chamber tube mill in the Burglengenfeld cement plant in an extremely confined space

Sulfate optimization of cements using isothermal calorimetry

Investigations on concretes containing fly ash for use in Qatar