Time: April to September, 2022
Location: Thailand
Equipment Model: ZM40 (LM Series Vertical Coal Mill System)
Production Capacity: 35 TPH to 50 TPH (Tons Per Hour)
Raw Material: Raw Coal (Feeding Size: 0–25 mm)
Moisture content: Input 40%; output: 15%, raw coal: 0-25mm
Final Production: 200mesh, 1% moisture
In Thailand industrial pulverized coal preparation industry, high moisture raw coal treatment has always been the core problem restricting enterprise production. The humidity of local raw coal is generally high, and the traditional pulverized coal production line generally has problems such as insufficient drying capacity, low production efficiency, large energy consumption loss, obvious fluctuation of finished product quality, etc. At the same time, traditional equipment occupies a large area, has cumbersome operation and maintenance processes, and has prominent safety and environmental protection risks, which seriously restricts the normal and stable production of enterprises and reduces overall operating efficiency.
In view of the complex raw coal conditions in Thailand, ZOOMLINE customized the ZM40 raw coal drying pulverized coal production line for customers and successfully put into operation in 2022. The equipment is specially designed for high-humidity and high-load raw coal processing scenarios, stably achieving 35-50TPH mass production capacity, and can finely process ultra-high moisture raw coal with local moisture content of 40% into high-quality pulverized coal with moisture content of 1% and fineness of 200 mesh. The project successfully solved the core production pain point of Thai customers and created an integrated pulverized coal preparation solution with high efficiency, low energy consumption and high stability, becoming a benchmark case in the field of high moisture raw coal processing in Southeast Asia.
The local Thai industrial enterprises cooperated in this cooperation focus on industrial pulverized coal processing and supply, and the products are widely used in upstream and downstream industries such as local cement plants, thermal power plants, industrial boilers and metallurgical manufacturing. With the continuous expansion of business scale, the technical shortcomings of the original traditional pulverized coal milling production line of the enterprise are fully highlighted. The six core production bottlenecks not only restrict the upgrading of production capacity, but also are common problems commonly faced by Thailand’s pulverized coal processing industry:
Traditional pulverized coal equipment has a single drying structure and limited dehydration capacity, which can not fully dry high-humidity raw coal, and it is easy to have problems such as incomplete drying and excessive moisture content of materials. The moisture content of pulverized coal finally produced is not up to standard, which cannot meet the strict material standards of downstream industrial production, which directly leads to the decline of product qualification rate and affects the order delivery of enterprises.
The original production line of customers adopts the traditional ball mill split layout. The drying, crushing, grinding and grading equipment are independent and scattered, and the overall area is huge. Enterprises need to invest high capital to build standardized large-scale production plants, with high capital construction cost, low site utilization rate and low return on investment of the overall project, which increases the investment pressure of enterprises in the early stage.
Traditional ball mill equipment transmission structure is old, energy conversion rate is low, power loss is serious in the production process, and daily power consumption costs remain high. For industrial enterprises with long-term large-scale production, continuous high energy consumption continuously compresses production profits, causing serious energy waste and greatly reducing the overall economic benefits of enterprises.
The grinding residence time of traditional coal powder production line cannot be accurately adjusted, and it is easy to have problems such as over-grinding and uneven grinding, resulting in large fluctuations in the fineness and moisture content of finished coal powder, and the 200 mesh finished product throughput is unstable. The uneven product quality cannot provide stable raw material support for downstream production lines, which is easy to cause chain problems such as downstream production stagnation and substandard finished product quality, which affects the stable operation of customer industrial chain.
The traditional pulverized coal production line adopts an open production structure, which is prone to dust leakage during the production process, which not only causes raw material loss, but also has serious dust explosion safety hazards. At the same time, the equipment operates with high vibration and excessive noise, which cannot comply with Thailand’s local industrial safety production regulations and environmental protection emission standards, leaving the company with long-term operational risks of compliance rectification and production suspension control.
The traditional equipment has low automation degree, highly relies on manual operation, and the labor operation and maintenance cost remains high. In addition, the replacement of wearing parts of equipment, the complicated routine maintenance process, the long operation and maintenance time, and the long downtime period of equipment seriously affect the continuous operation efficiency of the production line, resulting in a large number of capacity vacancies and economic losses.
In view of the above production pain points, Thailand customers have determined the core objectives of equipment upgrading through field research, equipment comparison and capacity accounting. They plan to completely get rid of the production shackles of traditional equipment through a new intelligent and integrated pulverized coal production line, so as to achieve cost reduction and efficiency improvement, compliance production and quality upgrading:
To meet the raw coal conditions and production needs of Thai customers, ZOOMLINE rely on years of vertical coal mill R & D and manufacturing and overseas project landing experience, customized ZM40 raw coal drying pulverized coal integrated production line for customers. The equipment abandons the traditional split old design and adopts an integrated, intelligent and energy-saving innovative structure. The six core solutions accurately target all production pain points of customers and comprehensively realize multi-dimensional upgrading of production efficiency, product quality, safety and environmental protection and cost control.
In view of the processing problem of 40% ultra-high moisture raw coal in Thailand, ZM40 raw coal drying pulverized coal production line is equipped with a built-in closed-loop hot air drying system, which directly introduces high temperature hot air into the coal mill to realize synchronous grinding and drying of raw coal and sufficient heat exchange. Without additional drying equipment, the moisture content of raw coal can be reduced from 40% to 15%, and finally high-quality pulverized coal with moisture content as low as 1% can be stably produced. While thoroughly solving the core pain points of incomplete drying of high-humidity raw coal and substandard finished products, the equipment procurement cost and plant floor space are greatly saved.
ZM40 raw coal drying pulverized coal production line adopts innovative vertical integrated structure, integrating multiple processes such as material crushing, hot air drying, fine grinding, powder classification and closed transportation into one, completely solving the disadvantages of scattered layout and large occupation of traditional ball mill equipment. Compared with traditional production lines, the equipment can save about 50% of the plant area, greatly reduce the capital investment of customer plant construction and site transformation, effectively improve the site utilization rate, and adapt to the large-scale production needs of various scale plants.
The core of the equipment adopts a direct pressure grinding structure between the grinding roller and the grinding disc. The transmission path is short and the energy loss is low. The energy transmission efficiency is greatly optimized. Compared with traditional ball mill equipment, the power utilization rate is significantly improved. The measured data shows that ZM40 production line can achieve 30%-40% power saving effect, reduce the energy consumption cost of enterprise normal production from the root, and achieve outstanding long-term economic benefits, perfectly solving the pain point of high power consumption and high operating cost for customers.
Relying on short material residence time optimization design + automatic intelligent control system, the equipment can monitor and accurately adjust the core parameters such as grinding fineness, drying temperature, material moisture content, etc., and the staff can quickly intervene in the production state to effectively eliminate the problems of over-grinding, uneven grinding, dry and wet of materials. The equipment can stably output standard 200 mesh pulverized coal, the finished product pass rate is stable at 80%-95%, the batch product quality is uniform, and the problem of large fluctuation in finished product quality of traditional equipment and inability to adapt to high-end downstream production is completely solved.
ZM40 raw coal drying pulverized coal production line adopts fully closed loop sealed production design, from raw material feeding to finished product discharge process is closed, completely eliminate the pulverized coal dust leakage, effectively reduce the loss of raw materials and the factory dust pollution. At the same time, it is equipped with high-standard explosion-proof system, which is targeted to adapt to high-risk working conditions of pulverized coal processing, so as to comprehensively avoid potential safety hazards of dust explosion. The equipment has been optimized for shock absorption and noise reduction, with small operation vibration and low noise, which fully conforms to the local industrial safety production and environmental protection emission standards of Thailand, helping customers to realize compliance and green production.
The whole production line is equipped with full-automatic electrical detection and intelligent control system, supports 24-hour remote real-time monitoring, unattended and stable operation, and greatly reduces manual operation cost and human error risk. At the same time, the equipment is equipped with automatic oil cylinder and rotating arm quick disassembly and assembly structure, so that wearing parts such as grinding roller sleeve and lining plate can be quickly disassembled and replaced, which greatly simplifies the daily maintenance process, shortens the shutdown time of the equipment, and ensures the continuous, efficient and stable operation of the production line.
Comprehensive support efficient production of ZM40 raw coal dry pulverized coal production line for ZOOMLINE independent research and development of integrated intelligent equipment, a complete set of system by the raw coal feeding system, hot blast stove heating system, raw coal drying system, raw material storage system, vertical coal mill core grinding system, fly ash collection system, pulverized coal airtight storage and transportation system, electric intelligent control system, explosion-proof safety system and utilities of ten subsystems together, each module linkage collaboration, Seamless connection.
The equipment is accurately adapted to the working condition of Thailand’s high-humidity raw coal, can process 0-25mm particle size raw coal, stably realize 35-50TPH mass production output, and provide solid hardware support for the implementation of the whole set of customized solutions and efficient and stable production.
Since it was officially put into production in September 2022, Thailand ZM40 raw coal drying pulverized coal production line has been in stable operation, and various production indicators, quality indicators and energy consumption indicators have exceeded customers ‘expectations, comprehensively solving various production pain points of customers in the early stage, bringing remarkable capacity upgrading, cost optimization and market value improvement for enterprises. The return on investment effect is outstanding.
The equipment for stably processing high-moisture raw coal can stably maintain 35-50TPH continuous production capacity for a long time, perfectly meet the processing demand of 40% ultra-high moisture raw coal raw materials in Thailand, thoroughly overcome the industrial problems that traditional equipment cannot efficiently process high-moisture raw coal, intermittent production and insufficient production capacity, and ensure all-weather large-scale continuous production of the enterprise.
Relying on the vertical integrated compact structure, the equipment effectively saves 50% of the plant area, greatly reducing the cost of plant infrastructure and site reconstruction; compared with the traditional ball milling equipment, it saves 30%-40% of electricity, and greatly reduces the long-term energy consumption expenditure. With the convenient replacement structure of vulnerable parts, the equipment shutdown maintenance time is significantly shortened, the manual operation and maintenance cost is continuously reduced, the comprehensive operating expenses of the enterprise are reduced in an all-round way, and direct economic benefits are created.
The production line stably produces 200-mesh standard coal powder, and the moisture content of the finished product is strictly controlled within 1%. The powder has uniform particle size, stable quality and few impurities. High-quality and standardized pulverized coal products can be continuously and stably supplied to downstream customers such as cement plants, thermal power plants and metallurgical enterprises, helping customers stabilize order resources, improve product reputation and significantly enhance the competitiveness of enterprises in core markets.
Avoid compliance risks, and match professional explosion-proof dust removal system with closed production structure of the whole line. There is no dust leakage, low noise, low vibration and clean and safe production environment in the whole production process. Since the project was put into operation, there has been no safety accident and no environmental protection exceeding standard, which fully conforms to the local safety production and environmental protection management and control standards in Thailand, helps the enterprise to completely avoid the operation risks such as compliance rectification, shutdown punishment, etc., and realizes long-term compliance production.
The ZM40 raw coal dying and pulverized coal production line is suitable for multiple types of coal raw materials with strong compatibility. It can flexibly cope with the subsequent production demands such as raw coal raw material fluctuation, capacity expansion, product specification adjustment, etc., and can adapt to the coal powder supply scenarios of cement, electric power, metallurgy, heat supply and other industries, reserving sufficient development space for the subsequent capacity upgrading, business expansion and market extension of customers. It has long-term use value and expansion value.
There are many brands and rich types of pulverized coal processing equipment in Thailand. After multi-party equipment comparison, scheme evaluation and field investigation, the customer finally chooses to cooperate with ZOOMLINE to implement ZM40 raw coal drying pulverized coal production line. The core advantages are mainly reflected in the four dimensions of customized scheme, equipment technology, full-cycle service and project delivery capability:
In the early stage, ZOOMLINE technical team deeply investigated the core working conditions of high moisture and difficult drying of local raw coal in Thailand, abandoned the industry universal standardized template scheme, optimized the equipment drying system, grinding structure and wind control system, customized the exclusive solution suitable for local complex working conditions, and the fit degree and landing effect of the solution far exceeded those of the same industry general equipment.
ZM40 vertical pulverized coal production line has significant differentiated technical advantages, integrating drying, grinding, grading and conveying, and has multiple advantages such as small land occupation, low energy consumption, stable production capacity, excellent quality, safety and explosion protection, simple operation and maintenance, etc. Compared with the traditional equipment and similar competitors, it has lower comprehensive use cost, stronger long-term operation stability and higher return on investment, and has outstanding product competitiveness.
ZOOMLINE provides full-process one-stop project landing service, covering preliminary working condition survey, personalized scheme design, equipment precision manufacturing, whole-process logistics distribution, on-site installation and commissioning, professional training of operators, post-stage normalized after-sales operation and maintenance, and full-chain closed-loop service, greatly reducing the difficulty and landing risk of customer projects.
Relying on years of experience in R & D of industrial pulverized coal preparation equipment and landing of overseas projects, ZOOMLINE vertical coal mill has mature technology, strong working condition adaptability and equipment stability verified by a large number of field projects. The enterprise has standardized mass production capacity and standardized project delivery system, which can complete equipment delivery, installation and production in strict accordance with the agreed period, effectively avoid project delay risk and guarantee project progress and production benefit for customers.
The successful and stable operation of Thailand ZM40 raw coal drying pulverized coal production line, it fully verifies the professionalism, practicability and advancement of ZOOMLINE customized solution for high-moisture pulverized coal preparation. The equipment accurately overcomes the common pain points of the industry such as difficult drying of high-humidity raw coal in Southeast Asia, high energy consumption, large land occupation, unstable quality, tedious operation and maintenance, etc. By virtue of integrated intelligent design, advantages of energy saving and consumption reduction, safety and environmental protection performance and stable capacity output, it has become the preferred benchmark equipment in the field of industrial pulverized coal preparation.
The equipment not only perfectly adapts to the local production conditions of high-moisture raw coal in Thailand, but also can be widely adapted to various processing scenarios of complex coal quality and high-moisture raw materials in Southeast Asia, and can comprehensively serve the large-scale production needs of high-quality pulverized coal in cement, steel, thermoelectric, metallurgy, central heating and other industries, with strong scene adaptability.
If your enterprise is faced with difficulties in processing high-moisture raw coal, high production energy consumption, limited plant site, large fluctuation of finished coal powder quality, high equipment operation and maintenance cost, please consult ZOOMLINE. In combination with your actual raw coal working condition, capacity demand and site conditions, we will customize exclusive pulverized coal preparation solutions with high efficiency, energy saving, low cost and high stability, so as to help enterprises reduce costs and increase efficiency and realize high-quality compliance production.
