Investment Cost and Site Requirements for Building a Small 3R Raymond Roller Mill Plant

　　Small 3R Raymond roller mills are widely applied for powder processing of non-metallic ores such as limestone,barite,talc and bentonite.In the early planning stage of a new powder processing plant,it is necessary to take various rigid site standards into comprehensive consideration and sort out all capital investment sections of the project.The following provides a detailed explanation combined with production demands of the equipment.

　　I.Rigid Site Requirements for Plant Construction

　　1.Plant Floor Size and Floor Height Requirements

　　A complete set of standard 3R Raymond roller mill production line adopts an integrated vertical layout,consisting of main machine,fan,classifier,cyclone collector,pulse dust remover and matching pipelines.The plant floor height shall match the overall height of the equipment,with reserved space for equipment hoisting and later maintenance.The indoor area needs to be divided into four functional zones:main machine placement,raw material stacking,finished product storage and packaging operation.

　　If only the basic main machine is arranged for simple processing,the space occupied by the equipment foundation is relatively compact.If a full set of devices including pre-crushing,bucket elevator,automatic silo and full-automatic packaging are equipped,the overall usable area needs to be expanded,and material transfer passages shall be reserved to prevent crowded stacking of materials and equipment from affecting continuous production.

　　2.Ground Foundation and Load-bearing Standards

　　The equipment generates continuous vibration during operation.The plant ground must be poured with thickened cement to ensure flatness,and reserved positions for pre-embedding anchor bolts of the equipment in advance.Shock-absorbing bases can be added at areas with concentrated vibration to ease overall machine vibration and reduce problems such as ground cracking and equipment displacement.The plant ground shall be treated with anti-seepage and dust-proof measures,which can not only avoid powder penetrating into the ground and difficult to clean,but also facilitate daily powder recovery cleaning.

　　3.Functional Zoning Planning of the Plant

　　A complete processing plant shall be divided into four independent operation zones:

　　--Raw material stacking zone:Used to store block raw ores with rainproof shelters built to prevent raw materials from getting damp and fluctuations in the fineness of ground powder finished products;

　　--Main machine production zone:For placing the complete set of 3R Raymond roller mill equipment,with maintenance passages reserved around for convenient daily replacement of vulnerable parts such as grinding rollers and grinding rings;

　　--Finished product storage and packaging zone:Equipped with finished product silos and packaging equipment.Powders of different mesh sizes shall be stored separately to avoid mixing materials and affecting product quality;

　　--Auxiliary matching zone:Power distribution control room,spare parts storage area,dust removal water circulation supporting area.

　　4.Site Conditions for Environmental Protection and Power Supply Matching

　　--Space for dust removal matching:Independent installation positions shall be planned for pulse bag dust removal equipment and dust removal pipelines.The height of exhaust stacks shall meet environmental protection testing specifications,and a dust settlement buffer area shall be reserved in the plant;

　　--Power supply matching:Multiple motors of the complete set of equipment run synchronously,requiring an independent power distribution room with special three-phase power supply lines laid and reserved installation positions for transformers and distribution cabinets;

　　--Ventilation and noise reduction:The plant shall maintain good ventilation,and a noise reduction buffer area shall be reserved at the edge of the plant to meet environmental inspection standards related to dust and noise.

　　5.Basic Supporting Conditions of the Site

　　The site shall go through formal industrial land procedures to guarantee stable supply of water and electricity.It shall be far away from residential areas and ecologically sensitive regions to reduce the impact of dust and noise.Internal roads of the plant shall be unobstructed to allow normal loading and unloading of raw material and finished product transport vehicles.

　　II.Overall Investment Composition for Plant Construction

　　1.Main Investment of Complete Set of Equipment

　　There are two configuration schemes with obvious differences in investment scale:

　　--Simple basic configuration:Only equipped with 3R Raymond roller mill main machine,fan,classifier,cyclone collection equipment,simple dust remover and electric control cabinet,suitable for small-batch processing projects with qualified raw material particle size;

　　--Full-process integrated configuration:Added with pre-crushing equipment,bucket elevator,electromagnetic feeder,storage silo,automatic packaging machine and closed pulse dust removal system to realize full-automatic continuous production,suitable for long-term stable large-scale processing.

　　The investment level of equipment is mainly affected by wear-resistant material of accessories,automation degree,supporting grade of environmental protection dust removal and integrity of the complete set of equipment.

　　2.Site Infrastructure Investment

　　It includes plant construction,ground hardening,special concrete foundation for equipment,plant enclosure,raw material rainproof shed,finished product warehouse,reconstruction of power distribution room,hardening of plant internal roads,anti-seepage drainage engineering,etc.Self-owned sites can greatly reduce infrastructure-related expenses,and renting ready-made compliant plants can save civil construction links.

　　3.Environmental Protection Supporting Investment

　　To meet environmental inspection standards of dust,noise and wastewater,supporting facilities including closed dust removal devices,noise reduction facilities,spray dust suppression systems,circulating sedimentation tanks and transformation of special solid waste storage areas are required.The higher the environmental control standards,the larger the proportion of investment in supporting facilities,which is an indispensable investment section for new powder processing plants.

　　4.Pre-operation Supporting Investment

　　--Installation and commissioning:Expenses related to equipment hoisting,pipeline erection,circuit wiring,on-site complete machine commissioning and construction of embedded foundation parts;

　　--Initial spare parts:Reserve vulnerable accessories such as grinding rollers,grinding rings,shovels,sealing parts and fan blades before production to guarantee uninterrupted operation of the production line;

　　--Formalities and qualifications:EIA filing,handling of relevant production compliance formalities and procurement of plant safety protection facilities;

　　--Working capital:Raw material procurement,finished product turnover,daily water,electricity and consumables,reserve funds for manual operation.

　　5.Long-term Continuous Operation Costs(Fixed Expenses after Production)

　　Plant rental or site maintenance,regular equipment maintenance lubricating oil,periodic replacement of vulnerable parts,water and electricity energy consumption for production,regular replacement of dust removal consumables,manual operation and management,operation of environmental protection equipment and other expenses.Long-term operation expenses directly determine the overall profit level of the project.

　　III.Practical Suggestions to Reduce Plant Investment and Optimize Site Layout

　　--Start-up projects with small production capacity are preferred to rent standardized ready-made industrial plants to save the civil construction cycle and reduce large infrastructure investment;

　　--Processing projects with small incoming particle size can skip the pre-crusher,simplify production line configuration and cut equipment investment;

　　--Adopt integrated closed dust removal equipment to reduce the floor area of multiple sets of dust removal devices and lower investment in environmental protection supporting facilities;

　　--On the premise of meeting equipment maintenance and material transfer demands,compactly plan each functional area to control the total plant area and save site-related expenses;

　　--Select vulnerable parts made of high-wear-resistant alloy materials to extend the replacement cycle of accessories and reduce long-term consumable operation costs.

　　The investment for building a small 3R Raymond roller mill plant is divided into one-time fixed investment and long-term operation floating expenses.Site planning shall focus on three rigid conditions:floor height,ground load bearing and environmental protection zoning.In the early stage,the equipment supporting scheme can be flexibly adjusted combined with self-owned production capacity demand,raw material particle size and local environmental protection requirements,the site layout can be reasonably optimized,the investment in early plant construction and post-production operation and maintenance costs can be balanced,so as to build a small powder grinding production line matching self-owned processing capacity.