Local Mineral Raw Material Self-Supply Grinding Station Built For Brazilian Multi-Industry Manufacturer
As one of the countries with abundant limestone reserves in South America, Brazil’s local construction, cement and light manufacturing industries maintain long-term stable growth. Before cooperating with us, the client’s group purchased limestone powder from scattered small grinding plants all year round, facing unstable powder fineness, delayed delivery and uncontrollable raw material cost. In order to realize independent raw material processing, unify product quality and cut long-term procurement expenditure, the group planned to build a large-scale integrated vertical mill grinding station near its limestone mine.
Our technical team carried out on-site ore sampling and full grindability test for the customer, and finally matched heavy-duty vertical roller mill as core grinding equipment. Instead of pursuing extreme maximum capacity of 44 tons per hour for blind high output, we set the daily stable production load at 24 tons per hour. This steady load design avoids long-term overload wear of grinding rollers and grinding table, effectively extends the service life of all wear-resistant spare parts, and reduces the frequency of overseas spare parts ordering for the factory.
The production line adopts local mainstream two-shift working mode, with two 8-hour production periods every working day, and one hour reserved for equipment maintenance and cleaning. Under continuous stable operation of 24t/h, the factory can produce about 384 tons of standard limestone powder every day. The powder fineness can be freely adjusted between 100 mesh and 420 mesh, which can simultaneously supply raw materials for cement workshops, construction mortar factories and paper making production lines under the group.
Integrated Station Layout And Complete Equipment Supporting Configuration
The whole grinding station adopts layered steel frame integrated design, combining raw material storage, feeding, grinding, powder selection, dust removal and finished powder storage into one complete automatic system. All equipment, conveying pipelines, sealing accessories and electrical control systems are supplied as a complete set, without the need for customers to separately purchase auxiliary equipment locally. Two professional technical engineers were sent to the site to guide the whole installation and commissioning work, and the whole production line reached full stable production within 29 days after the goods arrived at the port.
The closed-loop production flow realizes zero manual transfer of materials, and the specific equipment configuration and operation indicators are as follows:
Core Grinding Equipment: Heavy-duty vertical roller mill with three sets of wear-resistant roller assemblies
Stable Hourly Output: 24 tons/h, adjustable range 14–44t/h, adjusted according to limestone hardness and finished powder mesh
Daily Output Of Qualified Limestone Powder: Around 384 tons, 16 hours effective production in two shifts
Adjustable Powder Mesh Range: 100–420 mesh, online adjustment without stopping the whole station
Maximum Feed Particle Size: Limestone raw ore ≤42mm after primary crushing
Production Operation Mode: Fully sealed negative pressure circulating grinding, low dust overflow inside the workshop
Complete Supporting Equipment: Raw ore silo, quantitative belt feeder, vertical roller mill, high-precision powder classifier, large pulse bag dust collector, induced draft fan, PLC intelligent control cabinet, finished powder storage silo, multi-layer safety operation platform
Unique Advantages Of This Multi-Purpose Limestone Grinding Scheme
Stable Load Operation Reduces Long-Term Wear And Tear Cost
For large mineral processing stations in overseas areas, frequent replacement of vertical mill wear parts will bring high international logistics and shutdown losses. By controlling the daily stable output at 24t/h, the equipment avoids long-term overload operation, greatly slows down the wear speed of grinding rollers and lining plates, and extends the replacement cycle of core wear-resistant accessories by nearly 40%, which effectively reduces the annual maintenance budget of the factory.
Full Set Complete Delivery Shortens On-Site Construction Cycle
All steel frames, pipelines, flanges, sealing gaskets and driving motors are pre-assembled and tested in our factory before delivery, with unified standard interfaces. Local construction teams can complete assembly and docking directly without additional cutting and welding transformation, which greatly shortens the construction period and helps customers put the production line into formal supply faster.
Matched Large Dust Removal Unit Meets Local Environmental Supervision Standards
Brazil has strict regulatory restrictions on industrial dust emissions in mining areas. We matched a large pulse bag dust collector matching the air volume of the vertical mill unit, so that the whole production line runs under fully closed negative pressure. There is almost no floating dust in the production area during normal operation, and the project passed the local environmental acceptance at one time after commissioning.
Intelligent Simplified Control Lowers Operator Training Threshold
The supporting PLC control cabinet adopts intuitive touch operation panel, which can clearly display real-time data such as feeding speed, powder fineness and main motor load. We provided four days of on-site hands-on training for factory operators, and ordinary production staff can independently operate and monitor the whole vertical mill station without complex professional knowledge.
Main Application Fields Of Finished Limestone Powder
The limestone powder produced by this station is supplied to multiple industrial branches under the customer’s group, covering multiple mature downstream markets in Brazil:
Raw material filler for ordinary Portland cement production
Inorganic aggregate raw material for building mortar, precast concrete components
Lightweight filling raw material for paper making and coating processing industry
Road base stabilizing filler for municipal infrastructure construction projects
Global Full-Service Turnkey Support For Vertical Mill Grinding Station Projects
We have delivered a large number of vertical mill full grinding station projects to all regions of the world, and can flexibly adjust the supporting scheme of production lines according to local climate, environmental policies and factory operation habits. Before shipment, all overseas projects will complete factory pre-assembly and aging tests to ensure complete matching of main machines and accessories. Professional technical engineers can be dispatched to provide full-cycle on-site installation guidance and operator training. Original factory wear-resistant spare parts are supplied at factory direct prices all year round, with stable global sea freight logistics to shorten the delivery cycle of accessories.