ENTER A NEW DIMENSION – LOESCHE CCGpublications.worldcement.com/pdf/world-cement/2017/CPOTF/ptf17cp.pdf · The LOESCHE Compact Cement Grinding plant (CCG) plant – globally recognised

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CEMENT PLANTSOF THE FUTURE

A SUPPLEMENT TO WORLD CEMENT

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ISSN 0263 6050

THIS MONTH’S COVER

CONTENTS05 Comment

06 The Cleanest Cement Plant in the WorldWorld Cement’s Joseph Green visits the Kirchdorfer Cement plant in Kirchdorf an der Krems, Austria, to see the offi cial opening of the DeCONOx system developed by Scheuch.

11 Solving the CCS ChallengeTahir Abbas, Cinar Ltd, UK, explores the use of new technologies and research in enhancing energy effi ciency and reducing emissions in the cement industry.

21 Lowering the LimitJürgen Lauer, BWF Envirotec, Germany, reveals a new approach to dust and NOX control in the cement industry, as emissions limits continue to tighten.

25 The Future of FuelsHannes Uttinger and Christina Kastner, A TEC Production & Service GmbH, Austria, discuss maximising solid alternative fuel fi ring with new technology made in Austria.

29 The Search for Global SolutionsChris Mason, Votorantim Cimentos, North America, reports on an algae-based pilot as cement producers seek fresh answers to emissions challenges.

34 As Time Goes ByNeville Roberts, N+P Group, The Netherlands, explores where the cement industry has come from and predicts how it might continue to change in the future.

38 Committed to the FutureClaire Mathieu-André, Fives Group, France, provides an overview of the company’s commitment to developing the plants of the future.

43 Loading in LampungLeo Carnevale, FLSmidth Ventomatic, describes a terminal installation for PT Holcim Indonesia Tbk.

47 Expert Analysis for Mill OperatorsDietmar Freyhammer, David Martínez Parrondo, Sebastian Michelic, and Wilfred Zieri, CEMTEC Cement and Mining Technology GmbH, Austria, introduce a new tool to assist plant operators in improving product quality and lowering operational costs.

52 A First for BorneoCyrus Wiecko, Christian Pfeiffer, Germany, reports on the successful handover of East Malaysia’s fi rst integrated cement plant.

58 Predicting the FutureChristoph Muschaweck, DALOG, Germany, introduces the plant protection concept: online condition monitoring for the cement plant of the future.

63 Picking Up Good ConnectionsPerry Zalevsky, OSIsoft, USA, discusses how the facility of the future can help cement manufacturers to move forward.

67 Scanning for SuccessLisa Newhouse, PENTA Engineering Corp., USA, explains how to use 3D scanning and modelling technology for design and building success.

71 Productivity Goes DigitalNicholas Holst, FLSmidth Operation & Maintenance, Denmark, considers how next-generation technology platforms and upskilling plant staff can help today’s cement producers achieve a competitive advantage.

75 The Digital TwinPatrick Logerot, Snef Group, France, explores the future of green cement plants, which rely on digitalisation to reduce energy requirements and increase CO2 credits, by providing a centralised, shared knowledge of the equipment used.

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JONATHAN ROWLAND, EDITOR

COMMENTWe live in a time of remarkable development in the industrial space. The Industrial Internet of Things and Big Data are starting to redefi ne what is possible, changing the way manufacturers understand their operations. Meanwhile, new business priorities – particularly on the environmental side – are challenging the ways energy intensive industries have traditionally worked.

It is with this in mind that I would like to welcome you to Cement Plants of the Future. In it, we take three broad themes and explore how the cement industry is

developing in these areas. The themes are: the environment; plant and equipment engineering; and data and the digital plant.

On the environmental side, we begin with a tour of the plant that claims to be the cleanest in the world: the Kirchdorfer cement plant in Kirchdorf an der Krems in Austria (pp. 6 – 10). World Cement visited last year on the opening of the plant’s DeCONOx system, an innovative process that reduces various emissions to a minimum.

As well as an obvious environmental benefi t, the H7.3 million DeCONOx plant also provides a social benefi t, allowing the plant to be a good neighbour to the town around it. As the article concludes, Kirchdorfer “truly represents a cement plant of the future in its consciousness for the environment and its engagement with the community at large.”

On the plant and equipment engineering theme, Fives Group’s Claire Mathieu-Andre explores some of the more macro issues facing plants of the future (pp. 38 – 42), while articles from FLSmidth Ventomatic (pp. 43 – 46) and Christian Pfeiffer (pp. 52 – 55) tour recent state-of-the installations of their technology at a packing plant and cement grinding plant, respectively.

All this brings us to perhaps the prevailing theme of our time: digitalisation. Data can now be collected in unprecedented quantities, but how a company uses this data varies greatly, as Perry Zalevsky of OSIsoft explains (pp. 63 – 66). Zalevsky identifi es three different types of companies based on their use of data: collectors, optimisers, and transformers (a fourth type of company, which Zalevsky doesn’t put a name to, considers “any investments in technology or analysis as money down the drain”).

At the top level – the transformers – are companies that combine data from operations with enterprise applications and/or sales data, as well as data from sensors or systems, such as HVAC or lighting, that do not run through a control system, to gather a “comprehensive insight into their enterprises” and thus “improve fi nancial viability.”

Although Zalevsky concedes there are few companies that currently hit this level, ultimately, he concludes that, “getting accurate, real-time data into the hands of decision makers across a cement company will smooth the path into the future.” It is perhaps this “democratisation” of data that is the biggest change from the past – and the hallmark of a true cement plant of the future, as another of this month’s authors, Snef Group’s Patrick Logerot, concludes (pp. 75 – 79): “The connectivity revolution in smart plants has huge implications. The disclosure of information […] rewrites the balance of power in the factory by gathering maintenance staff, operators, and IT teams […] building a collective intelligence towards an optimised and effi cient cement plant, with a reduced environmental footprint.”

Logerot’s comments bring us full circle back to the environment – and, in the end, each of the three themes presented here overlap and interlock to produce an integrated view of what a cement plant of the future will look like. I hope you enjoy the articles presented here. As always, I’d welcome your views on this fascinating topic so do drop me a line and let me know how you view the cement plant of the future.

WORLD CEMENTNT’S’SJOSEPH GREEN VISITS THEE KIRCHDORORFEFEF R R CECECECEC MEMMM NT PPLALALANTNT IIN NKIIRCRCRCRCRCHDHDHDHDH OROROO F ANANAN DDDERER KREMMMMMS,S,S,S,S,S AAUSTRIA, TO SESEEE E E THTHHHHEEEEEE OFOFOFOFO FIFFF CICIALALAL OPOPOPOPOPPENENENENENININING OFF THE DECOOCOOCOONNNONN X SYYYSTTSTSTEMEMEMEME DEDEDEDEDEVEVEVEVEV LOLOLOLOPED BYYYYY SCCSCCSCCHEHEEEEUUCUCUCU H.H.HHHH

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quqquieiet.t. AAt t fi first t innspspecce titionoo ttthihihis s s scscscenenennee e iisis nnotot tthe usuuuus alalalal seettttininngg for a cecememem nttnt ppplalalanntnt. . HoHoHowewweveveer,,, tthehe KKKirrirchcchdodddorfrferer plplp aannnt tt t issisis iiiinnnn nnononoo wwwwayayay uuususualal.

InIn OOctobberer 2201016,66, WoWoWorlrlrldd d CeCeCeCememememem ntntn wwasassttininininvivitetedd toto tthehe oooffiffifificccciaiaiaial l l l opopopopenenenininining ggg g offofof ttthehehe DeDeCOCONONOx plpllplanananant t t t atatatt KKKKKiiriririrchchchddodorfrferer CeCemeentnt. OnOnOnOn aaaa bbbbeaeaeaeautututu ifififififullululul ssssununununnynynynyy ddddaayayay ininin KKKiri chchdodoorfrrf,, iniiinvivitetedddd gugugugueseeststs, , sosomeme drdrdreeseessesed d inin ttttrararararaddidididititititititionononoonono aalalala AAAAususususu trtrtrriaiaaannnn n atattitirere, , , gaagagag ththththererereredededed ooooututututsisisisidededede

/ 7

Cement Plants of the Future8 \ World Cement

the new facility to listen to technical explanations and welcoming speeches. The new facility represents another example of Kirchdorfer Cement’s determination to become as environmentally friendly as possible. It is this attitude that parallels so closely with the vision of what a Cement Plant of the Future should be. Throughout the evening it became clear that the company spares no amount of effort or engineering skill when it comes to environmental protection.

Kirchdorfer CementKirchdorfer Cement has produced cement for 127 years and, for many decades, the management of the company has set in place measures to reduce the company’s impact on the environment. One of the primary reasons for this focus was the proximity of the site to the city centre of Kirchdorf an der Krems (600 m). Over the years, the company’s careful and considerate approach to the

environment and its resources has become a natural awareness and part of the fabric of the company’s identity. In 2010, the management and the owner announced the primary vision to become the most energy effi cient cement plant with the lowest emission level and highest safety standards in Europe.

With the help of a DeCONOx system, a unique facility was installed at the plant for industrial exhaust air purifi cation and heat recovery. The system uses the energy from exhaust air to break down pollutants, such as nitrogen oxides or organic compounds. The residual energy is then recycled back into the production process and decoupled through heat recovery. Waste heat of about 20 GWh/year can therefore be fed into the district-heating grid of EnergieAG Wärme Upper Austria to supply over one thousand households in Kirchdorf and its surroundings.

In 1997 the fi rst pilot clean gas catalyst for the cement industry was placed into operation at Kirchdorf. In the coming years and as the next logical step, special activities and measures were taken in regard to pollutant emissions and air purifi cation. In September 2016, the fi rst large-scale facility for air purifi cation with the new DeCONOx technology was put into operation in the cement plant. The system was developed by the Upper Austrian plant manufacturer, Scheuch.

DeCONOx combines the advantages of a clean gas catalyst and regenerative thermal oxidation (RTO) within one facility. The advantages include the following:

Minimal exhaust of nitrogen oxides (NOX), organic carbon compounds (VOCs) and carbon monoxide (CO).

Low operating costs. Low energy demand.

An important part of the corporate vision of Kirchdorfer Cement was to tackle the energy supply of the cement works by steadily decreasing fossil fuel carriers. With the commissioning of the facility, a large part of this vision has come to fruition.

DeCONOx facilityThe DeCONOx process combines regenerative thermal oxidation (RTO or RNV) with a low-dust selective catalytic reduction (SCR): two proven technologies in a single system that fulfi ll two totally different tasks in exhaust gas purifi cation. This combination makes it possible to reduce organic carbon compounds and carbon monoxide. The installation of catalysts also reduces the NOX concentration. The demand for energy in the afterburning is mainly or entirely covered by the fuels – CO, VOCs – contained in the fl ue gas, thus reducing the energy demand compared to pure low-dust SCR. The system will run autothermally with around 6500 mg/Nm³ CO in the fl ue gas.

The DeCONOx plant consists of fi ve towers, two of which are pressurised with crude gas (before the reaction/combustion) and two of which are pressurised with clean gas (after the reaction/combustion). The fi fth tower is purged with clean gas to avoid peaks of

Project data

Costs: €7.3 million. Steel: 365 t. Regenerator and cathalyst stones: 215 t. Hoisting of ammonia tank: 500 t crane. Work hours: approximately 25 000 hours.

Figure 1. Aerial view of the Kirchdorfer cement plant.

www.cemengal.comwww.plugandgrind.com

AD_BOOK_ICR_2017.ai 1 20/2/17 11:15


crude gas concentrations (during switchover cycles) and thus reduce the half-hourly mean values (emissions). Organic hydrocarbons and the carbon monoxide are converted in the combustion chamber at above 850˚C. In order to guarantee complete oxidation, the combustion chamber is set to 860˚C. During start-up (heat-up) and non-autothermal operation, the temperature in the combustion chamber is regulated by burners or gas lances.

The special burners only need natural gas during operation, but not during standstill. With a combustion chamber temperature above 750˚C, the temperature can also be regulated with installed gas lances. Gas lances enable a fi ne-tuning of the temperature profi le across the burning chamber and do not need any burner air, thus reducing the energy demand even further. The clean gas

escaping DeCONOx is 25 – 35˚C hotter than crude gas.

Before start-up, the chamber is heated with natural gas and fresh air. This takes about 6 – 12 hours. Energy is lead through the burner into the combustion chamber. The maximum heat-up rate of 6 k/min should not be exceeded because of material stress. As soon as the temperature on the catalyst reaches 250˚C and the temperature in the combustion chamber is beyond 850˚C, the facility can be pressurised with fl ue gas. During standstills and maintenance work, the plant must be rinsed with fresh air.

Regenerators serve the temperature transfer. During the cycles they are alternately heated up and cooled down by the fl ue gas. The catalysts are installed between the regenerators (into the optimum temperature frame). The geometric set-up of the catalysts corresponds with the set-up of the regenerators. Thus, the catalysts work as regenerators and replace parts of the regenerators. The catalyst must not be damaged in the course of permanent switching procedures and the temperature changes involved. The switchover is carried out every 50 – 120 sec., during which the gas absorbs heat with the upward fl ow and releases the heat with the downward fl ow. In the bottom regenerator, the crude gas reaches the necessary catalyst inlet temperature of at least 240˚C. The ammonia injection and the catalyst layer is then followed by a second regenerator layer that then raises the fl ue gas to the combustion chamber temperature.

Selective catalytic reduction is the most effective method for controlling NOX emissions from combustion sources. It is a commercially proven fl ue gas treatment technology that has been demonstrated to remove over 98% of the NOX contained in combustion system exhaust gas. The catalyst is at the heart of the SCR process. It creates a surface for reacting

the NOX and ammonia, and allows for the reaction to occur within typical fl ue gas temperature ranges.

ConclusionKirchdorfer Cement plant seems to be so far removed from the norms seen in the majority of cement plants around the world. Even the immediate surroundings of the plant seem alien. Crisp green lawns meet quaint fountains that encircle the plant. Visitors could be forgiven for forgetting that they are on the doorstep of a cement plant. The plant chose to invest millions into environmental projects when the plant was already well below legal limits in terms of emissions and, as such, truly represents a cement plant of the future in its consciousness for the environment and its engagement with the community at large.

Figure 2. Five tower DeCONOx facility.

Figure 3. Schematic diagram of the gas passages based on the fi ve tower version.

Table 1. Technical data of heat recovery

Parameter Warm side Cold side

Thermal output 5300 kW

Mass flux 156.176 kg water/hr 116.407 kg water/hr

Temperature inlet 106˚C 65˚C

Temperature outlet 77˚C 104˚C

CCS CHALLENGESOLVING THE

IntroductionCement manufacturing is one of the world’s most energy and emissions intensive industries. Its share of national energy use in the USA is typically ten times greater than its share of the nation’s gross output of goods and services. This is extremely high compared with the energy consumption of other energy intensive industries which, on average, is only twice their share of gross output (Figure 1).1 Further, more than 60% of the electrical energy demand is for the crushing and grinding of raw materials, cement clinker, and solid fuels (for example, coal or petcoke). The energy consumed during clinker grinding alone accounts for almost two thirds of the total for grinding processes. From a fi nancial perspective, about 60% of the cost of cement production relates to power consumption. This represents a normally

unaccounted for source of CO2 emissions that are released by a power plant, usually located elsewhere.

Cement producers, through their associations, have reacted positively to the above analysis by producing evidence that, during the lifespan of a concrete structure, approximately 85% of the CO2 emitted during calcination is reabsorbed when concrete is carbonated, with about 50% of this being reabsorbed within a short timescale after concrete is crushed during recycling operations.2 Cement constituents are only a fraction of the ingredients of concrete. The contribution of sand, stone, and water, which are almost always locally available, to CO2 emissions during construction phases is negligible.

The cement industry has progressively reduced CO2 emissions through continuing process energy effi ciency enhancement and the increased use of alternative

TAHIR ABBAS, CINAR LTD, UK, EXPLORES THE USE OF NEW TECHNOLOGIES AND RESEARCH IN ENHANCING ENERGY EFFICIENCY AND REDUCING EMISSIONS IN THE CEMENT INDUSTRY.

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fuels and raw materials (AFR). For example, by 2030 the LafargeHolcim group aims to reduce net specifi c CO2 emissions (per tonne of cement) by 40%, against a 1990 baseline. By the end of 2015, the group had attained 26% of this target.

Further CO2 reductions may be achievable before reaching a threshold of negative effects on cement (e.g., toxic metal leachability, inferior concrete properties) or reaching a ceiling on the availability of a preferred AFR. In this respect, the use of more energy effi cient and light-weight concrete, known as hempcrete, is being considered. It replaces clinker, and hence saves energy, but is unsuitable as a load bearing material. It is prepared by chopping the woody core of the hemp plant into inch-long pieces and mixing these with a hydraulic lime binder, in the ratio of one part hemp to two parts binder, together with a small amount of water. However, the limited availability of hemp wood restricts its use. It is a site-mixed material, and as such, is ideal for small-scale ‘green’ construction projects, but it is highly unlikely to be adopted commercially. Another upcoming development stems from nanotechnology, where the use of micro

nano-materials (MNMs) offers the possibility for the development of new cement additives, such as novel superplasticisers, nanoparticles, or nanoreinforcements. These techniques can be used to effectively control concrete properties, performance, and degradation processes for a superior concrete and to provide the material with new functions and smart properties currently unavailable. Additionally, the introduction of these novel materials into the public sphere through civil infrastructure will necessitate an evaluation and understanding of the impact they may have on the environment and human health.3 In the future, there will be a gradual increase in the use of nanotechnology-based additives in the construction sector, as they have superior material properties and applications, and hence produce better quality cement, for lower energy consumption, leading to reduced CO2 emissions.4

An IEA report forecasts that each cement plant will need to reduce its emissions by around 1100 tpy CO2 from 2050 onwards.5 Carbon capture and storage (CCS) constitutes the only plausible means of achieving this.6 CCS offers a potential reduction of CO2 emissions from a typical cement plant of between 660 – 940 tpy. For a seamless adaption of CCS, extensive R&D is required to ensure

its economic viability. In this respect, a promising avenue, termed ‘oxyfuel’, is being explored. Oxyfuel involves combustion under oxygen-enriched conditions, combined with product recirculation to moderate temperature. This procedure reduces the cost of the carbon capture element of CCS by increasing the concentration of CO2. The scientifi c community has been investigating the CCS option for several years, led by ECRA (European Cement Research Academy), which involves detailed process analysis and mathematical modelling, as well as pilot-scale tests by leading European R&D establishments and cement producers. The IEA Greenhouse Gas R&D Programme (IEAGHG), through its international collaborative research programme, has also explored the cost-effectiveness of CCS technologies for several industries.

An on-going project, LEILAC (2016 – 2020), sponsored by the EU, is looking at capturing nearly pure CO2 from the calcination of coarsely ground limestone (CaCO3) through indirect heating. The project aims to demonstrate that, in the presence of steam, which acts as a catalyst, CO2 release from CaCO3 can be achieved at much lower

Figure 1. On average, energy intensive industries’ share of US energy consumption (bottom) is twice that of their share of gross output (top); cement’s share of US energy consumption, however, is ten times more that its share of gross output. Source: US Energy Information Administration (EIA), Bureau of Economic Analysis.

WWW.SCHEUCH.COM

Scheuch GmbH

Weierfing 68

4971 Aurolzmünster

Austria

Phone +43 / 7752 / 905 – 0

Fax +43 / 7752 / 905 – 65000

E-Mail [email protected]

As an international market leader in the ventilation and environmental technology sector,

Scheuch GmbH always keeps up to date with the latest industry technology.

The company provides trend-setting complete solutions for dust filtration and exhaust gas

cleaning for the entire cement production process. With the innovative EMC, DeCONOx and

Xmercury systems, the Austria-based company is once again proving itself to be a global

pioneer in the industry.

FOR THE INDUSTRIAL MINERALS INDUSTRIES

SCHEUCHCLEAN SOLUTIONS

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temperatures than 850˚C. A central calciner cylinder, supplied with coarsely ground limestone, is heated by fi ring fuels within a surrounding annular shaft.7 The LEILAC approach, although not yet proven, is certainly promising, but it facilitates the enrichment of CO2 from the calcination process only. Its combustion generated CO2 during the indirect heating of CaCO3, along with that from the combustion products generated during the clinker phase, needs to be dealt with by other CO2 enrichment and capture methods already developed in the power and cement sector, such a oxyfuel. Regardless of whether direct or indirect heating is employed, reducing the volume of gases by elimination of the air nitrogen is desirable, as it enables more compact and energy-effi cient equipment.

Future cement plants are envisaged to operate under CCS conditions and to incorporate compact kiln and pyroprocessing structures, onsite green power generation, AFR utilisation, and waste heat recovery (WHR). WHR is already well established. China, as a result of government policies, has the most plants with WHR installations. Due to its long production history and better alternative fuel (AF) specifi cations, Europe leads a global upward trend in the utilisation of AF, achieving a thermal substitution rate (TSR) average of about 20%, with some plants operating at 100% TSR. Similarly, increased use of cementitious materials, i.e., fl yash, pozzolans, and slag, is expected to reduce CO2 emissions by reducing the clinker-to-cement ratio. Clinker substitution has the potential to reduce CO2 emission by 5 – 10%. Once higher CO2 enrichment levels are achieved under carbon capture conditions of combustion, product recirculation and pure oxygen combustion (oxyfuel), CO2 storage/sequestration technology, extensively researched within a wide range of industries, is the main area requiring study.

Green power for cement plantsRecent data from Bloomberg and the World Economic Forum (WEF) reveals that the prices of solar and wind power as sources of clean energy have come down signifi cantly in many countries, including nearly 60 low-income ones.8, 9 In emerging markets, solar and wind are proving to be better than oil, gas, and coal,

despite the recent lower prices of these fuels. Just ten years ago, solar-generated electricity cost about US$600/MWh, whereas the cost of generating the same amount of power through coal and natural gas was only about US$100/MWh. In contrast, the corresponding costs of solar and wind are today respectively US$100/MWh and US$50/MWh. These price reductions are encouraging companies to invest in solar and wind. Admittedly, some of this price is competitively driven by government subsidies, particularly in the case of China, but, increasingly, renewable energy is both preferable and profi table (Figure 2). According to the Solar Energy Industry Association, the US is adding about 125 solar panels every minute.10

Clearly, reliability of supply is essential. Variations in energy demand are easily accommodated with fossil fuel and nuclear electricity generation. With solar and wind, one is at the mercy of nature. The only means of responding to increased demand when it is cloudy and/or calm is through recourse to a standby/backup system. In addition, the solar/wind reliability issue may stress the grid. For the cement industry, this is, however, usually of minor consideration, since plants are mostly located in remote locations, away from main cities. The local energy requirement of residents is normally less than 1% of that of the plant. Geothermal and hydro-power installations are, in principal, reliable sources of green energy, but they are usually remote from cement plants, and there are also ecological issues.

Several cement plants already have onsite green power generation. CalPortland has led the industry in energy effi ciency and green power initiatives by installing several wind turbines at its Mojave plant. These meet most of the plant’s overall power requirements. Cemex USA commissioned fi ve wind turbines in California with a total generating capacity of 7.2 MW, producing approximately 6% of its plant’s energy consumption.11 Cemex installed 67 wind turbines in Oazaca, Mexico, which supply 25% of the electricity consumption of 15 Mexican cement plants. A wind farm supplies over 50% of the power consumption of Lafarge-Holcim’s plant in Morocco. The 9 MW solar installation at Hanson’s Ketton cement plant in the UK was named the best

ground-mounted solar farm of the year in the less than 10 MW category of the Solar Power Portal Awards 2014.12

Cement plants operating under CCSAs mentioned, CCS ideally involves operation under oxyfuel conditions. A plant operating under full oxyfuel conditions, as studied by a project consortium in ECRA, Phase IV, is shown in Figure 3.13 The cement plant layout and structure remains the same, except for heat recovery, O2 separation, and additional

Figure 2. Global new investment in renewable energy: developed vs developing countries (2004 – 2005) (US$ billion). Source: UNEP, Bloomberg New Energy Finance.


ancillary equipment. N2 dilution resulting from air in-leakage is minimised by deploying high temperature seals. The clinker coolers have two sealed compartments. In one, hot CO2 enriched combustion products are drawn over the hot clinker, before entering the kiln and calciner as secondary and tertiary streams. In the other compartment, ambient air is heated and electricity is produced (i.e. ORC/KALINA, which are more effi cient at lower temperatures than the Rankine cycle). The waste hot gases are used for drying raw material and fuel.

The calciner is the most critical component when operating under CCS, as the meal retention time for effective calcination may be insuffi cient, especially under conditions of highly stratifi ed fl ow. This is due to the fact that CO2 enrichment inhibits the calcination reaction: the release of CO2 from CaCO3.

When considering the CCS option, the question arises as to whether suffi cient oxygen can be economically produced onsite? However, the cement industry has been using oxygen enrichment for years to burn ‘diffi cult’ fuels and for increasing production when the ID fan is limited. Also, CCS enables the use of more compact kilns, with lower heat loss and electricity consumption, further justifying oxygen production. Replacing the combustion air with pure oxygen and recycling the CO2 reduces the total volume of exhaust gases, enabling CO2 concentrations of 90 – 95%. CCS can be applied either to the full kiln system (including cooler, kiln, and preheater), or to the calciner alone, enabling up to 80% CO2 enrichment.

The effect on the calcination rate of higher CO2 partial pressures has been studied in laboratory-scale experiments, but without simulating the dynamic effects of turbulence, diffusion, and fl ow stratifi cation. Cinar Ltd has developed an in-house mineral interactive computational fl uid dynamics code (MI-CFD) for mineral industries. In the case of the cement industry, the calcination component of the code was originally

developed and validated for kilns and calciners operating under standard clinker production conditions. The calcination model has latterly been improved through deriving calcination reaction rates from an extensive set of literature data, where experiments were conducted under controlled CO2 enrichment and temperature conditions. Once the experimental calcination rates, as a function of temperature and CO2 concentration, could be predicted to a high level of accuracy, the improved calcination model was re-evaluated against all industry calcination data, including those for enriched CO2 concentrations relevant to CCS cement plants. The universal predictive power of the model has been shown to be excellent.

For calciners operating under oxygen injection and CO2 enrichment, the main concern has been whether existing calciners would have suffi cient residence time to achieve calcination levels of up to a 96%. The effects of oxyfuel operation, that is fl ue gas recirculation and oxygen injection, on the mixing and temperature are infl uenced by the specifi c geometry of the calciner and the injection locations of the fuels and oxygen in relation to meal inlets. MI-CFD predictions clearly show how the release of CO2 from CaCO3 continuously alters the temperature fi eld and gas species concentrations. Higher CO2 concentrations inhibit the calcination reactions, which in turn raise the gas stream temperatures. The increased CO2 concentrations also raise the gas density, thereby lowering the upward gas velocities. This has a positive effect on the residence time, compensating for the inhibiting of the calcination reactions due to the higher CO2 partial pressures.

Clearly, the numerous interactions are complex and can only be adequately assessed by the application of MI-CFD codes. The full results of the Cinar Ltd MI-CFD study of the application of carbon capture to cement plant are presented elsewhere.14 Here, simulated results are presented for a petcoke-fi red in-line calciner

operating with and without CO2 enrichment. The reason for selecting this calciner was that measurements of oxygen and CO2 concentrations, temperature, and calcination level were taken at three axial locations: just above the tertiary air inlet and just above and below the Venturi region. The kiln inlet conditions with and without CO2 enrichment are summarised in Table 1. The oxygen enriched stream (95% O2/5% N2) was introduced through a specifi cally designed calciner burner to increase the burnout of the petcoke, while maintaining similar levels of excess O2 for both the with and without CO2 enrichment cases.

Figure 3. Schematic of a full oxyfuel cement plant.Source: ECRA Phase IV, TR-ECRA-128/2016.

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Additional results for a clinker cooler and a different calciner design operating under CCS are presented elsewhere.15

Temperature, oxygen, and CO2 contours, for both with and without CO2 enrichment, are shown in Figure 4. The CO2 is increased in the regions where the meal particles are calcining.

A comparison between the two cases of the volatiles remaining, as shown in Figure 5, reveals that in the with CO2 enrichment case, the volatiles are quickly consumed, resulting in higher near burner temperatures that enhance the calcination, which would otherwise be lower due to the increased CO2 concentration. The overall heat release being the same, higher volatile concentrations below the tertiary air persist in the without CO2 enrichment case, whereas oxygen injected through the axial burner inlet rapidly consumes volatiles in the with CO2 enrichment simulation. The net result is only a 2% reduction in total calcination at the calciner exit (Figure 6): an extremely positive trend that, if observed otherwise (much higher reduction in meal particles’ calcination under with CO2 enrichment), would result in oxyfuel combustion unsuitable for cement plants, since calciners with much higher residence times would become uneconomical for CCS. Therefore, a calciner operating under CCS can be adapted/designed, while minimising

calciner fl ow stratifi cation and calciner burners, providing faster fuel(s) and enriched oxygen mixing characteristics.

The with CO2 enrichment case shows that the petcoke burns much faster (as indicated in Figure 6 by the colour change of the petcoke trajectories), due to the augmented oxygen concentration. The slight reduction in the observed calciner exit calcination levels (from 93 – 91%) and the corresponding increase in the temperature at the calciner exit (16˚C) could be further addressed, if needed, by improving the design of the oxyfuel burners, since a 6 sec. residence time is suffi cient to ensure both higher petcoke burnout and meal calcination levels, while operating in both the with and without CO2 enrichment modes. This is indicated, in both cases, by a lack of fuel/tertiary air mixing near the higher temperature regions.

Finally, following the mentioned calcination experiments and the validation of the MI-CFD code against their data, clinker production with and without CO2 enrichment was studied in a Fives FCB laboratory kiln, a small rotary kiln of 125 kW producing up to 15 kg/h of clinker, within the framework of ECRA Phase IV. During a two month trial, clinker was produced both under standard and oxyfuel conditions. The infl uence of false air and CO2 partial pressure on calcination and calciner exit temperatures were examined. Analysis of the clinker produced showed that there was no signifi cant difference between normal and carbon capture production modes. The consequences of the temperature shift in the calciner, as well as clinker formation in the kiln, were accurately predicted by MI-CFD calculations.

SummaryThe cement industry has, quite effectively, embraced dry short kilns, AF, raw materials, and other new technologies in its quest for enhanced energy effi ciency and reduced gas and particulate emissions. Current trends continue, with further advances in WHR, on/off-site green power, particularly solar and wind, cement quality and clinker

Table 1. Composition of gases with and without CO2

enrichment

Kiln gases Tertiary gas

Composition Without % v/v

With % v/v

Without % v/v

With % v/v

CO2 19.43 78.20 0.00 65.70

H2O - 7.40 0.00 1.30

O2 3.00 0.80 21.00 22.00

N2 77.56 12.00 79.00 11.00

Total 100.00 100.00 100.00 100.00

Figure 4. MI-CDF contours of temperature and oxygen without (left) and then with (right) CO2 enrichment.

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improvement through new additives and binders, and higher substitution rates of AF. Arguably, of greatest importance are R&D studies of cement plants operating under oxyfuel conditions, aimed at enabling the economical adaption of CCS. The application of CCS is the current challenge. New carbon capture based cement plants will be more compact, and so cheaper to build and operate. The primary diffi culty today centres on devising economic CCS procedures. However, promising technologies are being extensively studied within the framework of several R&D programmes initiated by governments, research institutions and industries. This assessment would change entirely if the CO2 capture and storage costs could be offset against higher CO2 trading

prices or environmental levies. At this time, it can be concluded that, assisted by MI-CFD, existing calciners can be successfully modifi ed to operate under CCS conditions or, alternatively, new ones can be designed that take advantage of the reduced size afforded by CCS. Once all the CO2 mitigation routes are implemented, CO2 emissions will no longer be an issue for the cement industry.

References1. EIA (U.S. Energy Information Administration): http://www.

eia.gov/todayinenergy/detail.php?id=11911

2. Nordic Innovation Centre, Project 03018.

3. SANCHEZ, F. and SOBOLEV, K., ‘Nanotechnology in concrete – A review.’ Construction and Building Materials 24 (2010), pp. 2060 – 2071.

4. ASHANI et al., ‘Role of Nanotechnology in Concrete a Cement Based Material’, International Journal of Nanoscience and Nano-engineering 2(5) (2015), pp. 32 – 35.

5. IEA, ‘Energy Technology Perspective’ (2012), http://www.iea.org/etp/

6. IEA, ‘Energy Technology Perspective’ (2012 – 2016).

7. www.project-leilac.eu

8. https://www.bloomberg.com/news/articles/2016-01-14/solar-and-wind-just-did-the-unthinkable

9. http://www3.weforum.org/docs/WEF_Renewable_Infrastructure_Investment_Handbook.pdf

10. http://www.eia.gov/todayinenergy/detail.php?id=25492

11. http://www.cemexusa.com/MediaCenter/PressRelease/wind-turbines-victorville-20130222.aspx

12. http://www.armstrongenergy.co.uk/news/ketton-solar-farm-named-best-solar-farm-of-2014/

13. Final report, ECRA Phase IV, TR-ECRA-128/2016.

14. Final report, ECRA Phase IV, TR-ECRA-128/2016.

15. AKHTAR et al, ‘Adapting Calciners Operating Under CO2 Enrichment for CCS’, Paper to be presented at 59th Annual IEEE-IAS/PCA Cement Industry Technical Conference, (21 – 26 May 2017; Calgary, Alberta, Canada).

Figure 6. Comparison of meal calcination without (left) and then with (right) CO2 enrichment. Without CO2 enrichment meal particles calcine to 93% and with CO2 enrichment to 91%. Meal particles are indicated by coloured lines, which change from blue to red as calcination progresses from 0 to 1.

Figure 5. Comparison of volatiles and petcoke burnout without (left) and with (right) CO2 enrichment. The lines indicate petcoke particles trajectories in a MI-CFD modelled calciner; the lines fi rst change of colour (from blue to red) indicate the completion of devolatilisation, and their second change of colour highlight char combustion (from blue to red). The same colour scheme is used for petcoke volatiles (red indicating the maximum concentration in the gas phase).

JÜRGEN LAUERR,,BWF ENVVIROROTET C, GERMANY,,REVEALS A A NEN W APPROACH TOT DUST AAND NOX CONTROL

IN THE CEMEMENT INDUSTRY,AS EEMIM SSIONS LIMITS

CONTINNUEU TO TIGHTEN.

IntroductionIt is a fact that emission limits in the cement industry have become – and will continue to get – more stringent. Although there are some differences, depending on what part of the world one looks at, the limits are undoubtedly heading downwards. A direct implication of this is that the dust control activities of cement manufacturers will have to be improved globally.

LOWERINGLOWERINGTHE LIMITTHE LIMIT

/ 21


Dust control technologiesIn cement plants across the world, cyclones, ESPs, and baghouses, either alone or in combination, are widely used dust control technologies, each with its own benefi ts. The well-known and established ESP technology is capable of handling dust emission limits of 5 – 10 mg/Nm3. ESPs in the cement industry can be operated up to a service temperature of around 450˚C, so there is no cooling of the gas needed for kiln exit gases and those of the clinker cooler. In the case of bypass fi lters, depending on the kiln exit temperature, cooling of the gases with air or water may be required. One of the most compelling arguments for an ESP installation is that ESPs are very easy to operate. Moreover, maintenance is relatively simple and the cost reasonable, due to fewer components involved as

compared to a baghouse, for example. On the other hand, the space requirements for an ESP fi lter are huge and, if one wants to lower the dust emissions even further, the fi lter becomes very large, and the consumption of electricity very extensive. The extension of an ESP to meet new emission limits could imply higher fi xed costs and increased operating costs. In most cases, the option of expanding the ESP fi lter is not available, as space is often the limiting factor in existing facilities. However, depending on the desired lower emission targets, ESP technology may not even be able to reach those new levels.

Finding other optionsTime and again, changes in regulations and lower emission limits have forced the industry to look for other solutions. Lower emissions, in the range of about 3 – 5 mg/Nm3, can be achieved with baghouses, which also have a much smaller footprint than ESPs. No wonder that one of the industry’s responses to the challenge was the conversion of an existing ESP installation, either in full or in part, into a baghouse with a fabric fi lter. This type of fi lter conversion has become common practice in the cement industry and, with new limits in place, many more retrofi ts are expected worldwide in the coming years. However, the right implementation is crucial to reaping the benefi ts of such a retrofi t. Some of the problems encountered can be traced back to fundamental differences between the two technologies. Two of these basic differences are the direction of fl ow of the fl ue gases and the operating temperature.

An ESP fi lter requires a horizontal fl ow of the fl ue gases going through the collecting plates. In a baghouse, the fl ue gases go through the vertically hanging bags. Therefore, in a baghouse fi lter, the gas fl ow should be vertical.

An ESP installation can be operated at approximately 450˚C whereas, in the case of a baghouse, the temperature is limited by the kind of fi lter media used. Maximum continuous operating temperatures for fabric fi lters are 250 – 260˚C; cooling of the fl ue gases is therefore required. The actual fi lter media may be a fabric cloth made of either a needle felt or a woven fi ber glass. Both fabrics could be equipped with an expanded polytetrafl uorethylene (ePTFE) membrane material. Due to the very small pore size of the membrane (1 – 2 µm), lower emission rates of about 3 – 5 mg/Nm3 can be achieved. The crystallite melting point of PTFE material is 327˚C and a potential active continuous service temperature of 288˚C seems possible. However, practical continuous fi ltration operating temperatures are between a maximum of 250 – 260˚C. In order to protect the fabric fi ltration media, valuable heat energy has to be wasted due to the cooling of the fl ue gas. In many cases, where cooling is done by air, about 30 – 50% of the air going through a fabric fi lter baghouse is the air required for cooling the fl ue gas to a desired temperature.

Figure 1. Pyrotex® KE elements in a baghouse.

Figure 2. Pyrotex® KE fi lter elements.

Figure 3. Urea or ammonia injection for SCR with Pyrotex® KE.

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Cooling of fl ue gas can be avoided, if the fi lter medium can withstand higher temperatures, presenting a number of opportunities:

The volume of air can be reduced, which saves electricity costs on the fan motor.

Increased production capacity may become possible without having to scale up the ID fan capacity.

The clean gases are higher in temperature and therefore do not need to be heated for potential SCR NOX reduction treatment. This will save on fuel consumption and therefore on cost.

The thermal energy from the clean hot gases can be reused as thermal energy for drying raw material or coal. Those clean hot gases could also be used to generate electricity.

Rigid filter elementsWell-established in glass manufacturing, but new to the cement industry, are rigid fi lter elements. BWF Envirotec’s tradename for this product is Pyrotex® KE. Very low dust emissions of less than 1 mg/Nm3 are achievable. These fi lter elements are made out of calcium-magnesium-silicate fi bres, which are non-carcinogenic and bio-soluble. Those fi bres are safe for human health.

The materials used for the manufacture of Pyrotex® KE fi lter elements can withstand high temperatures, making the elements thermally stable up to a continuous operating temperature of 850˚C. No cooling of fl ue gases is required and no thermal heat energy will be wasted. About 1 MJ heat energy could be saved per 10 t of clinker when replacing an ESP kiln fi lter with a Pyrotex® KE fi lter.

The BWF Envirotec Pyrotex® KE fi lter elements are of a low density, which manifests itself in a relatively lightweight construction. Due to this low-density construction, the air permeability of Pyrotex® KE fi lter elements is similar to that of fi bre glass with membrane material. A low differential pressure goes along with the high air permeability.

The fi rst successful commercial installation of Pyrotex® KE elements in a clinker cooler fi lter, with operating performance far exceeding the design parameters, especially a highly favourable differential pressure, has

paved the way for more to come. In this application, the cleaning pressure is about 2.0 – 2.5 bar with a resulting differential pressure over the entire fi lter of 10 – 12 mbar. Due to its excellent air permeability, the plant is experiencing only one full cleaning cycle per day. Furthermore, signifi cant savings in compressed air can be achieved and an extended life of the Pyrotex® KE elements can be expected.

The Pyrotex® KE elements are available in 60 and 150 mm dia. The top collar design can be built as V or T-shape (Figure 2). Traditionally, the V-shaped collar has been established in the glass industry. However, more and more T-shaped designs are being requested. This will make a replacement of regular fi lter bags much easier. The elements are available in various lengths, with the longest element available as a single 4.5 m piece. All elements longer than 4.5 m are designed modularly and put together onsite. 8 m elements are in the testing phase, while 6 m elements are already available for commercial installations.

In addition to a dust control performance of ≤1 mg/Nm3, the fi lter elements can be equipped with a catalytic converter material for SCR NOX abatement. When compared to a traditional SNCR, SCR NOX reduction can take place at a lower temperature of 200 – 450˚C, due to the use of the catalyst.

BWF Envirotec offers four different catalysts (Figure 4) that will work within that temperature window. When selecting a specifi c catalyst, the characteristics of the process gases will have to be reviewed and considered.

The Pyrotex® KE elements provide a single solution for dust emissions below 1 mg/Nm3. Combined with a catalytic converter, Pyrotex® KE elements can also take care of other gaseous emissions, especially NOX. Due to the ability of operating at elevated temperatures, even SOX reduction with calcium hydroxide (Ca(OH)2) can be optimised. The optimum temperature for SOX reduction with Ca(OH)2 is 350˚C, which is above the temperature that fabric fi lter media can handle; Pyrotex® KE elements, however, can. Since dust collection and gaseous emissions control steps can now be handled with a single dust control unit, the investment and operating cost for this type of fi lter will reach a new economical effi ciency.

It is BWF Envirotec’s experience that each process requires a tailored solution, especially when it comes to NOX reduction with SCR catalytic systems. The savings in heat energy will also be reviewed on an individual basis. In some cases, it is benefi cial to eliminate the cooling of the fl ue gases as the clean, hot gases are often used for material drying. When applying the Pyrotex® KE technology to hot cement clinker fi ltration, the clean, hot gases are used as combustion air for a different thermal process. An OEM specialising in cogeneration of electricity in a cement plant claims that the most economical approach doing this will start with a kiln size of at least 5000 tpd of clinker.

It seems obvious that with more and more stringent emission requirements different new technologies and solutions will enter the market.

Figure 4. Various catalytic systems for Pyrotex® KE.

THE FUTURE OF FUELSHannes Uttinger and Christina Kastner, A Tec Production & Service GmbH, Austria, discuss maximising solid alternative fuel firing with new technology made in Austria.

IntroductionWith the world’s cement industry constantly looking for ways to cut production-energy costs, there has been a strong move towards the use of alternative fuels (AF) over the last couple of years.

Co-processing of waste in cement kilns is already being widely employed across Europe, but nevertheless, the potential for further uptake is still large. One of the greatest advantages for the cement industry is the reduction of its fossil fuel consumption and therefore a reduction of environmental impact. Firing with materials, such as municipal solid waste (MSW), plastics, sewage sludge, biofuels, waste wood, used tyres, and other biomass, is on the increase, replacing more expensive traditional fuels such as coal. Latest studies show, for example, that if European cement plants increased their usage of AF up to 95% emissions of 41 million tpy of CO2 could be avoided.

But achieving this goal means overcoming several barries. On the one hand, there are infrastructural, political, and environmental hurdles; on the other hand, technical and economic ones. AF materials tend to have a high moisture content with a wide range of particle sizes that must be homogenised before they can be used for firing. There have been a few key innivations over the last couple of years showing that it is technologically and economically feasible to further increase this substitution rate, possibly as high as 95%.

/ 25


One of these innovations is the Rocket Mill RM 2.50 double®, which was developed by A TEC Production & Service GmbH. With its high reduction ratio, the Rocket Mill® produces AF particles ready for firing in one step. Easy to operate and maintain, it offers lower operating costs than

a complete shredder system, while allowing cement producers to achieve high fuel-substitution rates in their kilns and calciners.

First steps from waste to fuel A first step towards optimising the production of highly calorific residue-derived fuels for the cement industry was made in 2014. The cement producer, and long-time partner of A TEC for innovative solutions, w&p, Wietersdorf plant in Klein St. Paul, Austria, wanted to increase the substitution rate on the main burner from 40% up to more than 90% with solid AF. Subsequently, a prototype of A TEC’s mill was installed. The motivation for such a goal was a significant cost reduction, due to the high substitution rate of fossil fuels. The pilot project was successful in terms of CO2 savings and the reduction of environmental impacts. During that time, A TEC worked on the further development of the mill’s technology and was able to launch the first double chamber mill – the Rocket Mill 2.50 double® – in 2016.

Drying and grinding in one stepA TEC’s Rocket Mill consists of two robustly-designed grinding circular chambers, each of which is equipped with horizontally rotating chains and perforated screens. Since the Rocket Mill can accept feed up to 250 mm in size, only one pre-shredding or pre-sorting step is usually needed.

In operation, the feed is fragmented through impact with the rapidly rotating chains, as well as through inter-particle collisions. The screens surrounding the crushing chamber only allow particles of the required size to pass through. Any uncrushable material is automatically removed via slide gates from the chamber.

The output material from the Rocket Mill has advantages in terms of its fuel properties. The process creates particles with a high specific surface that improves ignition and combustion characteristics, while the heat generated within the mill helps to reduce the inherent moisture content of the feed from typically 25% to 15% in the fine material. Inorganics are separated from the AF during the shredding process and can be discharged during operation via slide gates.

Featuring twin crushing chambers, each powered by a 315 kW direct electric drive, the Rocket Mill® can produce up to 10 tph of AF, with a final size less than 15 mm. It is also possible to produce larger material, e.g. for a calciner with short retention times. This only requires a change of the screens, which can be easily done within two hours. The effect is a significant increase of throughput.

Maintaining the mill is easy and cost effective. A complete change-out of a set of wear parts takes less than two hours. The screens have a life time of

Figure 1. The A TEC Rocket Mill RM 2.50 double.

Figure 2. Details from the A TEC Rocket Mill RM 2.50 double.

Figure 3. Solid AF produced by the Rocket Mill.

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around 1000 hours and the chains 200 – 250 hours, depending on the material being crushed.

Installation at a waste treatment plantThe Austrian company, FCC Austria Abfall Service AG, installed A TEC’s Rocket Mill in its treatment plant in Wr. Neustadt in 2016. The aim was to

optimise the production of a highly calorific residue-derived fuels for the cement industry. All in all, the installation process took about two weeks. The mill was fabricated by A TEC’s plant construction site in Eberstein.

FCC used pre-sorted household and commercial waste, which is preshredded before entering the mill. This is followed by air separation and magnetic separation to ensure that only the wastewater fraction enters the Rocket Mill.

The mill in Wiener Neustadt operates with a screen of 15 mm and a size reduction from 250 mm to 15 mm can be ensured. Different output fuel particle sizes would be easily produced.

The solid AF from the Rocket Mill has three main advantages.

Change of physical propertiesDue to the mill using a 15 mm screen opening, approximately 50% of the produced solid AF is smaller than 5 mm. The crushing process creates particles with a higher specific surface that improves ignition and combustion characteristics (Figure 3, Figure 4 and Figure 5).

Drying while crushingA 10% drying effect occurs during the grinding process. For example, if the input material’s moisture content is 25%, it will decrease to approximately 15% after passing through the mill. This drying is performed using the heat generated during the crushing process. Additionally, hot gas from the pyroprocess can be injected into the mill, which results in additional drying of the solid AF. Drying the material has a beneficial effect in its ignition in the kiln, as well as in the flame temperature, as the lower heat value of the solid AF is increased (Figure 3).

Robust designOne advantage of this new technology is the separation of the ferrous and non-ferrous metals, as well as heavy 3D particles, from the AF during the shredding process.

The drying effect, combined with the robust design, results in an increase of the lower heating value.

Operational experienceFollowing the commissioning of the Rocket Mill RM 2.50 double in November 2016, the output material has already been tested by a cement plant near the FCC plant. The results were satisfying. The test showed that an immediate increase of the AF rate was possible, while retaining the clinker quality. Before using the high-quality output material from A TEC’s Rocket Mill, the existing rate could not be further increased because the clinker quality would have suffered. A second test is planned in March 2017.

Figure 4. Solid AF produced by a conventional shredder.

Figure 5. Relation of the mill’s output material to a coin.

Figure 6. Relation between lower heat value and moisture.

THE SEARCH FOR GLOBAL SOLUTIONS

CHRIS MASON, VOTORANTIM CIMENTOS, NORTH AMERICA, REPORTS ON AN ALGAE-BASED PILOT AS CEMENT PRODUCERS SEEK FRESH ANSWERS

TO EMISSIONS CHALLENGES.

IntroductionThe hunt is on for practical ways to reduce the emission of greenhouse gases from the cement manufacturing process.

St Marys Cement, a Votorantim Cimentos company with plants in Canada and the US, has invested in a bold demonstration project that shows how CO2 waste can fuel the production of valuable raw materials. The vital force inside this project is algae, nature’s most efficient carbon processor. These microscopic aquatic plants have the power to transform two tonnes of CO2 for every tonne of biomass they produce.

Can the emissions generated by cement kilns be used to feed algae that are grown, harvested and, perhaps, even processed onsite? Exciting new results from the St Marys pilot suggest that the answer is yes.

Creating a private-public partnership The St Marys project is Canada’s first algal biorefinery. The CAN$4 million, 1500 ft2 plant stands near the smokestacks at the company’s cement production facility in St Marys, Ontario, about 100 miles southwest of Toronto, in Canada.

Pond Technologies, an algae production company based in Markham, Ontario, developed the proprietary technologies that drive the pilot programme. Extensive technical support and resources also come from Canada’s National Research Council (NRC) through its Algal Carbon Conversion Programme. The St Marys plant provides the necessary space, raw materials, and in-house support needed to ensure the project’s smooth operation.

Untreated emissions from the plant’s kiln smokestack are channelled into a custom photobioreactor developed by the Pond Technologies team. Fast-growing algae inside the reactor consume the gases, creating biomass in the process, while releasing pure oxygen.

“As a carbon absorber, algae exceed any other option by a factor of 50,” explained Pond Technologies founder and CEO Steve Martin. “We now have a way of harnessing this waste product to create new resources.”

From raw emissions to valuable biomassFor the technology to be economically viable, Martin continued, the algae must be able to take in raw emissions from industrial smokestacks.

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“Raw emissions can contain sulfur dioxide, nitrogen dioxide, carbon monoxide, water, and particulate matter from incompletely burned fuel, along with CO2,” he explained. “We’ve proven that the algae can take it all without any difference in output.” This is crucial, as the extra step of separating CO2 from the emissions would make the costs of the process prohibitive.

At present, algae produced inside the St Marys plant bioreactor are sent to the NRC for study, but they may eventually be used to create valuable products, ranging from biofuel and animal feeds, to soil amendments, pharmaceuticals, and nutritional supplements.

Small footprint, massive outputAlgae thrive in light-filled, CO2-rich conditions, and the bioreactor at the St Marys Cement plant delivers exactly what the algae need.

The light comes from custom-fabricated, high-intensity lights that flash continuously. This tricks the algae into thinking the days are very short, triggering rapid growth, explained Peter Howard, Pond’s Vice President for Sustainability.

“Algae grow like any other organism, just at a tremendous rate – upwards of four to eight generations a day,” Howard said. “The process harnesses algae’s growth potential to produce high volumes of biomass.”

The bioreactor’s LED lights are so powerful they literally outshine the sun. Light is distributed evenly by mounting the units on rods that run the width of the tank.

“Ordinary sunlight can only penetrate the water-to-algae mix at a depth of 2 cm,” Howard explains. “By contrast, our bioreactor achieves 30 – 40 cm of penetration, yielding denser growth in the smallest footprint of any comparable bioreactor.”

Continuous harvesting of the algae is also essential for maximum output. The bioreactor at the plant is relatively small, holding 25 000 l of algae medium, so organisms are harvested at a rate equal to their growth to create a continuous bloom, Howard noted.

“Special sensors and proprietary algorithms give us a real-time growth rate that drives the harvest process,” he said. A centrifuge extraction process yields the paste-like algal biomass and recycles the processed water back into the system. Waste heat from the cement plant can then be used to dry the biomass, if necessary. Proprietary control systems manage every aspect of the bioreactor, including light delivery, growth, harvest, temperature, pH, nutrients, and gas injection.

A second commercial-scale facility“Though modest in scale, the St Marys pilot points to solutions that may soon have major global impact,” said Bill Asselstine, Vice-President, Technical, Safety, and Sustainability for Votorantim Cimentos’ North American operations.

While the current pilot captures about 1% of all CO2 emitted at the St Marys plant, plans to scale the technology are being considered, according to Asselstine.

The next step under discussion is a larger, commercial-scale facility at a St Marys Cement plant

Algae seed tanks.

Algal biorefi nery onsite at the plant.

Stack gases cooled and fed into the bioreactor.

There are no construction projects without cement, and no cement without Loesche vertical roller mills (VRM). Grinding of cement clinker and granulated blast furnace slag in vertical roller mills is a technology introduced by Loesche. Since the rst Loesche vertical roller mills came onto the market in 1928, countless num-bers of them have been used in the cement industry across the world. Nowadays more than 2,000 Loesche mills are in operation worldwide.

The extensively proven Loesche VRM is also the core of the new Compact Cement Grinding plant (CCG). Loesche’s CCG provides its technological features in a most compact form thus making them available in small but growing markets and remote areas with a demand for locally produced cement.

FROM THE PIONEER AND PACEMAKER IN GRINDINGThe Loesche CCG plant – globally recognised technology in its most compact form

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For further contact data and more information and support please visit us at www.loesche.com

18407-world-cement-210x297-gb.indd 1 10.10.16 11:21


in Bowmanville, Ontario, some 45 min. from Toronto. The proposed bioreactor would hold between 0.5 – 1 million l of algae medium and draw a greater percentage of carbon emissions from the plant’s fl ue stream, testing a process that would dry and pelletise the biomass onsite to produce animal feed.

The proposed plant would use a series of 25 000 l bioreactors to achieve high-volume biomass production. Up to 40% of build-out costs may come from a CAN$74 million clean tech initiative sponsored by the Ontario Centres of Excellence (OCE), the province’s primary agent for supporting new market opportunities for the commercialisation of cutting-edge technologies.

The OCE’s goal is to prove the commercial viability of algal conversion technologies, said Martin Vroegh, Senior Director, Greenhouse Gas Reduction Technologies for OCE and former Director of Environmental Affairs at Votorantim Cimentos North America.

“We want to see what types of products can be developed and, specifically, whether high-value products, such as nutraceuticals and high-protein animal feeds, can be created to support less profitable, yet equally important products, such as low-carbon biofuels.”

Algae used to create medications and nutritional supplements can be worth thousands of dollars per kilogram, Vroegh added – profits that might subsidise the manufacture of other useful products with lower market value.

Competing for global attention, funding The algae-based solutions have garnered international attention, carrying Pond Technologies to the semifinal stage of the US$20 million Carbon XPRIZE sponsored by NRG, a leading US-based integrated power company, and Canada’s Oil Sands Innovation Alliance (COSIA). This global competition is open to innovators working on breakthrough concepts that address climate change through products that convert CO2 emissions into viable new resources. OCE leadership has pledged an additional CAN$800 000 in funding to support Pond scientists as they develop technology for the next phase of the competition.

The effort reflects the urgent need for solutions – a situation that climate experts say cannot be ignore. By 2040, global energy demand will grow by 37% and, with construction activity ramping up, carbon mitigation solutions are becoming even more crucial to the health of the planet.

The same technology at work in the St Marys pilot may someday be used to successfully absorb CO2 emissions in other industries, said Stephen O’Leary, Director of the Algal Carbon Conversion Flagship Programme at Canada’s National Research Council.

Algae in beakers.

Pond team examines algae.

25 000 litre bioreactor tank with light controls.

“This technology could also be deployed at oil and gas facilities, aluminum smelters, oil sands fi elds – any sort of heavy industry,” he continued. In fact, smaller tests have already used unfi ltered stack gases from a steel plant and a power generation plant to produce algae.

“Everyone is looking for a silver-bullet solution,” said the OCE’s Vroegh “But the reality is that carbon abatement will come from a number of different technologies. End-of-tailpipe solutions like the St Marys pilot are just one part of a much bigger picture.”

Beyond algaeAccording to Asselstine, cement industry leaders are exploring multiple ways to reduce CO2 emissions. For the past 5 years, the company has produced a Portland-limestone cement known as Contempra. The process releases about 10% less CO2 by adding up to 15% limestone in place of clinker.

Portland-limestone cement has been incorporated into the standard building codes and specifi cations in Canada as a Type GU cement (known as Type I cement in the US). “Adoption is beginning to ramp up here, as we are now nearing double digits in sales,” Asselstine added.

Votorantim Cimentos’ North American cement plants are also incorporating low-carbon fuels into the mix at its plants in Bowmanville, Charlevoix, Michigan, and Branford, Florida. “Alternative fuels like lumber waste, plastic products, discarded consumer paper products and carpet-derived materials burn cleaner at high temperatures, and have the added benefit of keeping them out of landfills,” Asselstine explained.

Another technology the company is following closely is carbon-cured concrete systems that manufacture cement with less limestone at lower kiln temperatures.

These systems are reported to use less energy, while generating up to 30% less greenhouse gases and other pollutants than ordinary Portland cement. The resulting cement in the concrete mix is cured by injections of CO2. “Most applications we’ve seen have been at concrete block and precast operations,” Asselstine said. “But we’re also monitoring the results of cast-in-place operations in Canada and the US. All of this is part of Votorantim Cimentos’ and St Marys Cement’s ongoing legacy of making a positive, long-term impact on people and our planet, whether that involves our products, our processes, or helping to advance new technologies.”

NoteChris Mason is Communications and Brand Manager for Votorantim Cimentos’ North American operations.

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+ INNOVATIVESOLUTIONS

Neville Roberts, N+P Group, The Netherlands, explores where the cement industry has come from and predicts how it miight

continue to change in the future.

IntroductionIn recent years, I have had the privilege of working with other industries outside of the cement industry. My impression of the cement industry was that it was slow to adapt to change and could do better. Through my experiences elsewhere, however, I have concluded that this belief was incorrect. Indeed, I feel that, as an industrial sector, the cement industry has moved very quickly, and I have often been quoted as saying that it is among the greyhounds of the industrial sector. This fills me with great enthusiasm for the future. As my opinion may not be shared by all, I have here attempted to look at where the industry has come from when I first joined it in the 1970s, where it is now, and so extrapolate as to where it could be in the future.

Looking to the pastAs a chemical engineering undergraduate, I was seconded to a UK cement plant for my industrial placement in 1977. Little did I realise that I would be wedded to the industry for the vast majority of my working life. My impression of the entire industry at the time was that it was very big, very dusty and, in certain areas, very hot. I suppose I could sum up the entire industry in the following way.

The plants were relatively small, with plants of 3000 tpd looked upon as very large indeed.

Energy effi ciency was an issue, but was hampered by fundamentally ineffi cient processes (many wet process kilns were still in operation) and very little activity in the use of alternative fuels (AF). Indeed, on my fi rst cement plant I was told that a few years previously the plant manager had tried to introduce the concept of AF to the management team. From the comments I overheard, there was little enthusiasm, with one well-known member of staff only being worried about the smell. At another plant, where I later tried to introduce the concept, I was challenged by the production manager, who said to me in an open meeting: “the problem with you is that you think we are here to make money, the truth is, we are here to make cement!”

Environmental management was not a discipline at the time, with visits by the authorities being infrequent and emissions data kept on the plant without any public visibility. I remember once being in a meeting when the word dioxin was mentioned for the first time, with nobody in the meeting having the faintest idea what it meant, including me.

Manning was very high. With factories operating at ratio’s of less than 3000 tpy per man. On the flipside, the level of automation was minimal. Indeed, I remember that each cement bag produced by the plant was handled manually and automation for the packing plant

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was introduced some 5 years later. In addition, the concept of a fully automated kiln was a dream.

Finally, I witnessed many occasions where it was stated that good cement making was an art, and that to understand the process one had to live and breathe the operation, listening carefully to the senior operators, who were the only people that really knew how the process worked.

How far have we come?From this starting point it could be seen that the industry had to modernise or fail. It is sad to say that many plants did not modernise quickly enough and so perished; however, the remaining plants have modernised and the transformation has been astonishing when we compare it to the period described above.

Modern cement plants can be giants when compared to the plants of the 1970s. Kilns of up to 15 000 tpd of clinker have been installed using the latest technology.

The vast majority of kilns are highly thermally effi cient in terms of power consumption and kiln fuel effi ciency. In addition, the use of AF is becoming much more commonplace. I can remember when it was openly stated that kilns could not achieve more than 50% thermal substitution and that, at high levels of substitution, clinker production would be adversely affected. Both of these myths have been challenged in recent years, with plants achieving 100% substitution and the impact on clinker production being eliminated. Indeed, in some cases clinker production has increased when burning high levels of AF.

The other area of development within the cement industry has been the growing relationship between the cement industry and the waste management industry. There are now a number of examples where cement companies have long-term contracts with waste management companies to supply high-grade solid recovered fuel (SRF). One example of this is the long term contract through which N+P is exporting SRF from the UK to the Cemex Latvia plant in Broceini. In addition, the leading AF suppliers have changed their mindset and have rebranded themselves as AF suppliers, instead of being waste management companies that have to provide an alternative to landfilling and where the quality of the AF is not the top priority. This has been a major improvement in this part of the AF business.

Regarding environmental control, the use of AF has again benefited the cement industry, in terms of CO2 emissions, due to the burning of biomass, as well as in terms of NOX emissions, which can be reduced by more than 50%. Policing the environment is also much more advanced than some 40 years ago. In the modern, world the operating

permits are very detailed and frequent compliance meetings take place. In addition, emission limits are much lower, with many new components now controlled, including organic compounds. There are also many examples where the plant emissions are provided on a live basis to the authorities and examples where emissions are displayed on LED screens outside the gates of the cement plant.

With the increase in plant capacity, there has been a signifi cant increase in clinker produced, with fi gures of over 30 000 tpy of clinker per employee being achieved. This compares with the 20th Century dream target of 6000 tpy of clinker produced per employee.

Automation has moved on significantly, with expert systems operating at many clinker manufacturing locations and laboratories now routinely being fully automated. It has to be remembered that 40 years ago the internet did not exist, and neither did PCs, tablets or mobile phones, all of which are now fully utilised to run cement businesses.

What will the future look like?The previous summary really puts into context the advances made in the last 40 years and so offers encouragement that many big changes could be on their way during the next 40 years.

Kiln fuel consumptionOver the coming years, governments around the world will further recognise the importance of landfill avoidance and will adopt legislation, such as landfill tax, thus forcing industry to find alternatives to landfill. This will create a lucrative market in waste and so catalyse the development of AF industries globally. This will then enable cement companies to source good value AF locally and result in the majority of fuel consumed in the industry being AF. However, this could lead to AF shortages, affecting the price of this fuel.

Pelletised AF, such as the Subcoal being produced by the N+P Group BV, will be attractive to cement users due to its high quality, enabling kilns to burn at high substitution levels. The milling of Subcoal on vertical fuel mills, especially Loesche mills, will become commonplace and, indeed, will become the industry standard.

Cement plants will also adopt separate specialist milling of Subcoal, using prescribed milling systems, such as the Atritor coal mill. This approach will become the norm for plants that that do not burn fossil fuels and so will not require the vertical mill infrastructure mentioned previously. In addition, this will assist cement plants that want to mill Subcoal to a high degree separately to their primary fuel and so further increase the amount of AF that can be burnt.

Cement plants will form formal collaborations with waste management companies in order to have more control over the processing of the waste feedstock into AF and to move further up the value chain.

It is expected that cement plants will look to generate their own power by utilising waste heat. Where the finances are attractive, the cement industry will also move into waste-to-energy plant technology and use high value waste streams to generate the power they consume.

Environmental controlCO2 emissions are a major concern to the cement industry. It is therefore predicted that extra efforts will be made towards using raw materials that will reduce the amount of carbonate included within the standard kiln feed.

Extensive use of hydraulic additives will be more common, to minimise the amount of clinker used per tonne of cement consumed in another effort to reduce CO2 emissions.

Carbon capture and storage (CCS) technology will be used extensively throughout the industry in regions were receptors are available to store CO2. In addition, instead of using coal as a heat source it is anticipated that cement plants will use waste-to-energy technology for the CCS process,

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and so make the whole carbon capture system economically sustainable.

Perhaps a little scarier... Driverless trucks in the quarry and remote-control

shovel loaders. Expert control systems in operation on all kilns

with remote kiln operation at head office. Drones equipped with heat seeking capabilites

used to monitor the plant. Driverless cement delivery trucks. Kiln refractory improvements, such that kilns can

run for a number of years without refractory stops. Mobile phones will have the technology for

a message to be sent in one language and be immediately translated into another. This means a Welsh speaking engineer could speak to an engineer in China and be immediately understood.

ConclusionMaybe some of the suggestions are fanciful, but when the progress made over the past 40 years is analysed, anything is possible. I am sure that I will not be around to check these predictions in 40 years time, but good luck to those of you that make it. I am sure that you will have as exciting a career as I have, and I ask for you to be considerate when judging my forecasts.

COMMITTED TO THE FUTURECOMMITTED TO THE FUTURE

38 \

CLAIRE MATHIEU-ANDRÉ, FIVES GROUP,

FRANCE, PROVIDES AN OVERVIEW

OF THE COMPANY’S COMMITMENT

TO DEVELOPING THE PLANTS OF THE

FUTURE.

IntroductionFives has weathered three industrial revolutions since its creation in 1812, reinventing itself along the way. The group designed the fi rst steam locomotives and, later, the fi rst electric ones. It also contributed to the construction of several major 19th Century structures, including the Alexandre III Bridge in Paris, the hydraulic elevators in the Eiffel Tower, and the Tancarville Bridge in Normandy. The company now designs and supplies equipment and production lines to thousands of industrial plants worldwide.

As part of its continued commitment to innovation, the group invests f40 million in R&D every year towards developing innovative process equipment and production lines and contributing to building the plants of the future. Fives currently owns over 2000 patents, with a strong focus on energy performance, the environmental impact of industrial processes and, more recently, the introduction of increasingly advanced digital technology.

Fives is also committed to promoting sustainable industrial activity, a commitment that echoes its tradition of innovation. As a part of that commitment, in honour of its bicentenary in 2012, Fives opened a dialogue on the future of industry, with the creation of the Fives’ Plants of the Future Observatory.1

The Fives Observatory aims to foster positive conversations about industry and generate debate on the industry of tomorrow, bringing together experts from a wide range of backgrounds. Its events and publications feature contributions from a broad range of individuals and public personalities, including industrial leaders, corporate executives, economists, journalists, and more, whose original, sometimes surprising and always relevant contributions enhance the debate.

In 2013, Fives was asked by the French government to co-lead a programme intended to jumpstart the French industrial sector, with a focus on the industry of the future. This programme now offers support to companies as they modify their production equipment, particularly with digital technology. Frédéric Sanchez, Chairman of the Fives Executive Board, co-chairs the programme.

Challenges for the plant of the future...The plant of the future is emerging due to changes across all industrial sectors, traditional and less traditional, in response to new challenges. These changes are amplifi ed by the accelerated development of a number of, mainly digital, technologies. Beyond technology and equipment, this trend also affects business models, work, and organisations.

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The plant of the future is part of a new economic, social, and environmental dynamic, which defi nes its outlines. It must address challenges that include the strong need for economically competitive regions and businesses, changing consumption habits, and societal issues, including appeal and integration into the surrounding environment. Ultimately, the plant of the future can only be integrated into society by meeting environmental performance and energy transition objectives.

...and new technologies to address themRecent technological developments completely change the situation in terms of competitiveness and create new opportunities in developed countries, in both emerging and more traditional industries.

Digital revolutionThe digital revolution is an essential – or even founding – component of the plant of the future, because it is a major part of the response to the challenges discussed above. Embedded sensors in machines and products can provide real-time information on the production equipment’s status. Calculation resources, internet-based data transmission, and increasingly user-friendly mobile devices are making it possible to ‘virtualise’ plants and optimise their design, operations, any potential reconfi gurations, and maintenance.

The plant of the future will use connected machines: digital technology, integrated into all of the company’s processes throughout its value chain, can optimise production system performance throughout the plant’s lifecycle. It will go beyond using data to optimise

management of individual pieces of equipment to manage all materials and product fl ows. Software solutions and data can also be used for quality control and product traceability throughout the production line. Combining data analysis with digital simulation can refi ne economic management of the plant.

New materialsNew materials, such as composites and nanomaterials, also offer opportunities for the plants of the future. Aeroplanes currently include over 50% composite materials. It is still far from being the case in all industries, but producers are working with production equipment designers and manufacturers to enhance performance.

New processes: additive manufacturingAdditive manufacturing, also known as 3D printing, offers relief from many of the constraints of traditional machining. This new manufacturing process is growing fast. The current objective is to achieve industrial manufacturing of steel, aluminum, and titanium parts that have physical characteristics identical to those produced using traditional techniques, but with more complex shapes, which are impossible to produce with other techniques, and while still guaranteeing high-quality, high-speed production with minimal waste.

In 2016, Fives teamed up with Michelin to create AddUpp, a joint venture in metal additive manufacturing, which is a very high potential manufacturing process.

Eco-designEco-design is becoming standard in machine manufacturing. In 2012, Fives created the Engineered Sustainability® eco-design programme that recognises the Fives technologies that offer the best combination of environmental and operational performance. The brand is granted to technologies that have undergone a rigorous review of their environmental impact and areas for improvement, and a quantifi cation of their performance. The principles of eco-design are progressively being applied to all the equipment, technologies, and solutions offered by Fives group.

Physical and cognitive operator assistanceThe plants of the 20th Century are gone. Numerous technologies are currently being developed to strike the right balance between fully automated and fully manual production – and France is on the cutting edge of the trend. Cobotics (human-robot cooperation) makes work easier, while augmented reality can help operators fi nd information, remember what to do, and check and fi t parts. On an automotive assembly line, for instance, robots help operators insert the instrument board into the passenger compartment, while preventing any impacts that

Figure 1. 3D metal Eiffel Tower produced with AddUp additive manufacturing machine.

could damage it. Operators’ jobs are made easier and waste is reduced.

What role do operators play? Implementing these new processes and technologies requires the support of men and women, whose human qualities make them the essential coordinators of the plants of the future. Operators become supervisors: they are freed from diffi cult tasks or perform them with the help of robots, and can focus on monitoring fi nal product quality and machine status. Their role expands to include continuous improvement and innovation.

That means learning new skills and new ways of working related to using digital tools (wireless connections, mobile devices, 3D data visualisation, augmented reality) and helping to design new user interfaces, particularly for cobotics. Developing new training techniques, independent learning, and knowledge capitalisation for everyone within the organisation and chain of command is key to the successful implementation of the plant of the future and industry’s appeal.

The cement plant of the future

The environmentThe cement industry has started its transition to the industry of the future, particularly on environmental issues, which are the subject of increasingly tough

societal expectations and regulatory standards. Cement producers have been working on reducing their plants’ emissions of CO2 and other pollutants (NOX, SO2, mercury), as well as optimising their energy consumption (electricity and fossil fuels), for a number of years. Fives is developing innovative production systems that address these challenges at several different levels.

To go further in decreasing NOX emissions and to be able to meet future regulations, Fives has designed a new evolution of its FCB Zero-NOx Preca (Figure 4) with the D-NOX concept. It consists of deep air staging, with the combustion chamber operated at a lower air ratio and with a portion of about 20% of the combustion air directly fed to the goose neck. The Pillard Neutrinox™ SNCR system can also be added, if required, along with the extension of the length of the goose neck, to increase the residence time, allowing for the development of the reduction reactions. According to computation fl uid dynamics (CFD) models carried out at Fives’ Cement and Minerals Research and Testing Centre, the air staging can bring a 30% abatement of the NOX emission down to 350 mg/Nm3. With the addition of the Pillard Neutrinox™ SNCR, a 200 mg/Nm³ (at 10% O2) target is achievable without using a costly and constraining catalytic system.

High-performance production equipmentIndustrial equipment now meets environmental performance criteria, while continuing to meet


traditional cost and operational objectives. That is the essence of eco-design approaches, such as Fives’ Engineered Sustainability programme.

For the cement industry, the group has developed the FCB Horomill®, a grinding mill that uses bed compression technology (Figure 2). When associated with the FCB TSV™ Classifi er, TGT® Filters or with

FCB Aerodecantor to dry and classify, the grinding system can produce all types of cements, notably with various additives, with extremely high fi neness (over 7000 cm²/g), while reducing electricity consumption by 20% to 50% compared to market technologies. This is achieved with no water addition, which decreases cement quality. All of this with the guiding philosophy that environmental performance must be achieved without sacrifi cing product quality.

The production process as a whole must be both frugal (limiting the use of resources to the strict minimum) and effi cient (the resources must be fully utilised).

Increasing the cement additive levels (except clinker, which undergoes pyroprocessing), possible thanks to increasingly high-performance grinding workshops, can decrease its carbon footprint. Low-impact materials, such as waste and byproducts, can also be used as fuel, reducing costs (fossil fuels currently generate up to 30% of cement plant operating costs). The cement industry is already replacing the fossil fuels used in its kilns with a variety of waste and byproducts (tyres, plastics, biomass, used oils, etc.), which can account for up to 80% of the energy mix at the cement plant.

To better optimise the use of alternative fuels (AF), Fives offers burners like the Pillard Novafl am® (Figure 3), which can fi re up to 100% AF. In addition to reducing costs, using AF lines up with environmental objectives, such as preserving natural resources and cutting waste, while using the right high-performance technologies can reduce emissions of volatile organic compounds (VOCs) and NOX.

Fives can help companies switch their production systems to AF at any stage of the plant life cycle, in order to take advantage of the different fuel sources available, while ensuring continuous, fl exible production. The company also offers its own proprietary equipment, designed to guarantee effi cient ignition and combustion of AF. For example, the FCB Zero-NOx Preca can eliminate NOX emissions and limit other pollution, while guaranteeing stable combustion.

Going further: recovering waste heatMinimising heat loss and reusing waste heat within the process cannot entirely eliminate it. The next step is recovering the residual waste heat using external systems. This energy can be recovered and used in the plant or to meet the needs of other businesses or the surrounding area, but adding a waste heat recovery system should not have a negative impact on production quality or plant availability. The group has released a white paper on the issue,2 which highlights the challenges faced by and viable industrial solutions for the cement, steel, aluminum, and glass industries.

References1. www.plantsofthefuture.com

2. www.fivesgroup.com/innovation/whr.pdf

Figure 3. Pillard Novafl am® burner.

Figure 4. FCB Zero-NOx Preca.

Figure 2. Fives grinding plant featuring FCB Horomill® grinding mill associated with a FCB TSVTM Classifi er and TGT® Filter.

IntroductionHow to optimise cement dispatch on a limited plot of land? That is the difficult question PT Holcim Indonesia Tbk. had to answer when designing its Lampung terminal. The main issue was that the available area was limited, so there would be only a few parking slots for trucks waiting to be loaded with bulk or bagged cement. That meant an efficient solution had to be found to maximise the output of the plant, in terms of dispatching capacity. Moreover, a wide range of trucks had to be accommodated; flexibility was therefore not an option. To solve these problems, PT Holcim Indonesia Tbk. decided to team up with FLSmidth Ventomatic® as the EP supplier of the Lampung terminal (Figure 1).

The projectThe first task was to efficiently supply cement to the plant and store it: a pneumatic transport system fills a 10 000 t Ventomatic® inverted cone silo from self-unloading vessels. The solution was designed so that the compressors on the ship can unload the material without external help at high capacities of up to 250 tph. As power limitations are enforced in the Lampung area, the plant needed to be able to run with minimum power

Figure 1. Holcim Lampung terminal.

LEO CARNEVALE, FLSMIDTH

VENTOMATIC, DESCRIBES A TERMINAL

INSTALLATION FOR PT HOLCIM

INDONESIA TBK.

LOADING INLAMPUNG

/ 43


consumption. Potentially, such systems can be very energy intensive, so it was indispensable to supply a solution that would minimise power requirements.

The second issue was to optimise cement dispatch. The Ventomatic® logistics system ensures a seamless distribution, by tracking trucks through a system of badge reading from plant entrance to exit. Drivers are equipped with RFID badges, on which the type of cement, quantity, and form are stored, based on the orders. From the terminal’s entrance gate, trucks are guided to the inlet weighbridge, then to either the Ventomatic® inverted cone silo for bulk cement, or to the warehouse for bagged cement. Once loaded, trucks proceed to the outlet weighbridge for fi nal

verifi cation and check-out. All operations are recorded and made available for control and invoicing.

The third challenge was to offer very fast and fl exible loading solutions for both bulk and bagged cement. Here, the following solutions were implemented:

A Ventomatic® bulk loader (Figure 2) precisely fills bulk trucks. It is integrated into the silo to limit both equipment installed, and footprint. The interlock with the weighbridge underneath guarantees a high weight accuracy even at a capacity of 300 tph.

In the packing plant, an automatic high-capacity line is installed: a GIROMAT® EVO V12 twelve-spout rotary packer with vertical axis impeller – with an INFILROT® Z 40 shooting bag applicator – for a capacity of 3600 bags/hr of 50 kg each. These are dispatched to a POLIMAT® palletiser, fitted with a Ventomatic® Flying Fork-Lift FFL (Figure 3) automatic truck loader for stacks of bags, or to a manual truck loader for smaller vehicles.

Here, a revolutionary concept has been introduced to the market: a POLIMAT palletiser feeds bag stacks to the Ventomatic® Flying Fork-Lift FFL, which automatically loads them directly onto trucks without pallets (Figure 4). This greatly simplifies the logistics,

Figure 3. Ventomatic® Flying Fork-Lift FFL automatic truck loader for stacks of bags.

Figure 2. Ventomatic® bulk loader, with movable safety barriers and weighbridge.

Increased ProductionReduced PowerEnhanced Quality

MillScan Vibration Fill Level Measurement System

No Crosstalk IssuesZero Maintenance3 Minute Calibration

obsolete electronic ears!

Case studies and more informationavailable at digitalcontrollab.com


and reduces bag dispatch costs. Moreover, it allows the loading of trucks at the same capacity as the palletiser – in this case, 3600 bags/hr. Space required for the installation is also limited and storage space is minimised, as bags can be directly loaded without passing through the warehouse, solving the challenge of optimised bag dispatch on a limited plot of land.

This palletiser/loader combination also enables the plant to operate continuously, as trucks are loaded when present in the loading bay and the palletiser is used when no trucks are present. The palletised stacks are then moved by a forklift to storage using slip-sheets.

This solution has obvious benefits for the user:

100% packing line availability (regardless of trucks’ presence).

Highest dispatch flexibility and speed thanks to possibilities of direct loading to trucks, warehouse storage, or loading from storage to trucks by traditional fork-lift or Ventomatic® Flying Fork-Lift FFL.

Elimination of empty pallet logistics and costs.

Figure 4. Holcim Lampung packing plant layout.

Trucks with side walls can be loaded (impossible with traditional fork-lifts).

Minimal infrastructure needed as the equipment is installed on the ground floor.

Safe operating conditions.

Another interesting feature is a bag splitter, which divides the bag fl ow between the manual loader and the palletiser. This way, the line always operates at full capacity, even when small vehicles are loaded manually, as the excess capacity from the packer is sent to the palletiser.

The solution offered would not be complete without an advanced plant supervisory system. The operator in the cargo control room can constantly monitor the smooth operation of the Lampung terminal thanks to the Ventomatic® Plant Supervision System. The status and conditions of

each and every piece of equipment installed is shown in real time and messages are automatically displayed in case of deviation from normal operation. The supervision system also allows FLSmidth Ventomatic® Technical Assistance to remotely access the system in the unlikely case that troubleshooting is needed.

ConclusionPT Holcim Indonesia Tbk. and FLSmidth Ventomatic® have successfully partnered to set up a state-of-the-art cement terminal in Lampung, Sumatra. As a ‘One Source Supplier’, FLSmidth Ventomatic® has designed, engineered, and delivered a solution that matched all requirements of PT Holcim Indonesia Tbk., particularly optimising cement dispatch on a limited plot of land.

The system supplied offers flexibility, reliability and high efficiency at reduced costs. Its design allows the loading of any kind of truck, while allowing dispatch capacities of up to 3600 bags/hr.

In an increasingly competitive market, the Lampung terminal provides PT Holcim Indonesia Tbk. with an advantage, keeping operating costs low and attracting customers thanks to its new cement dispatch system.

EXPERT ANALYSIS F O R M I L L O P E R ATO R S

DIETMAR

FREYHAMMER, DAVID

MARTÍNEZ PARRONDO,

SEBASTIAN MICHELIC, AND

WILFRED ZIERI, CEMTEC CEMENT

AND MINING TECHNOLOGY GMBH,

AUSTRIA, INTRODUCE A NEW TOOL

TO ASSIST PLANT OPERATORS

IN IMPROVING PRODUCT

QUALITY AND LOWERING

OPERATIONAL COSTS.

IntroductionCement producers, especially the operators of cement grinding systems, are dependent on many factors and variables, including the chemical composition of clinker and additives, the moisture of feed materials, the particle size of feed materials, and that of the fi nished product. Furthermore, the cement grinding process requires a high-energy input, and so the cost of electricity has a major infl uence on production costs.

Effi cient mill operation therefore requires continuous adjustment to the varying operating conditions. Measuring and controlling the particle size distribution of the fi nished product, cement, is important for achieving the desired product performance at the lowest production cost possible.

/ 47


The problem with BlaineThe particle size distribution and specifi c surface have a large infl uence on cement performance. A historic technique for measuring the specifi c surface is the Blaine test. The Blaine test, however, has several disadvantages.

The Blaine value is just an indication of specific surface.

Cements with the same Blaine value may show different performance characteristics.

The accuracy of Blaine measurements is lower for finer cements.

Real-time measurements are not possible and operation adjustments lag 60 – 120 min. behind, depending on sampling frequency.

One of the most important characteristics of an analytical technique is its ability to differentiate between samples that perform differently within an application. However, two cement samples with an identical Blaine value can show different particle size distributions when measured by laser diffraction.

In the example shown in Figure 1, sample 2 contains more fi nes than sample 1, but also coarser material, resulting in both samples having the same specifi c surface. This illustrates why two samples with different particle size distributions can have the same Blaine value, but different cement properties.

The hydration speed of cement particles is a function of the particle size distribution and determines the strength of the set cement. In general, fi ner particles hydrate more quickly, giving greater strength, and so, within certain limits, fi ner cement is better cement.

Very fi ne cement particles in the range of 2 – 3 µm may cause exothermic cracking. On the other hand, particles over 50 µm may not hydrate, compromising product strength. Sample 1 contains fewer fi ne and coarse particles and consequently has superior cement properties, even though the Blaine value is equal to that of sample 2.

In a daily cement grinding operation, a sample is taken every one to two hours and the operator then receives the fi neness results measured in the laboratory and can take corrective action. Reducing the particle size of the cement too much, within limits, tends to improve its quality but requires signifi cantly more energy; this ‘overgrinding’ is typically the result of a late and poor grinding system control.

Developing an alternativeThe main driver behind the development of the CEOPS was its use in cement grinding systems. Nevertheless, it is now also available for other materials in dry and wet grinding applications.

The CEOPS is equipped with online laser analysis, providing real-time particle size distribution. This

Figure 1. Cement particle size distributions.

Figure 2. Typical installation of the CEOPS sampling device at the process fi lter discharge chute.

Figure 3. Particle sizer principle.

Figure 4. CEOPS visualisation.


enables the operator to identify and evaluate changing operating conditions and to take the necessary corrective actions or make adjustments in time.

Thus, operation efficiency is improved, production costs are reduced by operating the system at the desired fineness setpoint, which is measured in real time, and overgrinding is reduced.

Further measureable advantages of the CEOPS are as follows.

Stable cement quality. Decreased specific energy consumption. Faster automatic adjustment in case of cement

quality change. Increased production capacity. Decreased mill operator activities.

These improvements result in increased financial performance and usually, a return on investment for the CEOPS system in around 6 – 12 months.

The CEOPS system is a custom-made solution that is entirely engineered, developed and manufactured in Europe. The modular approach allows for quick and easy adaptation to any existing grinding circuit,

ball mill system, or vertical roller mill (VRM) system. The CEOPS system consists of:

An automatic sampling device. A CEOPS measuring unit with a highly developed

particle size characterisation laser. A CEOPS control system. An interface to the existing plant operation

system. A KMC high-performance control system

(optional) with mill level measurement. Recipe management (optional).

The optional KMC high-performance controller and recipe management enable a fully automatic grinding system operation.

Usually, the automatic sampling device is installed in the discharge chute of the product separation equipment, either a bag filter or a cyclone, to obtain a representative sample of the product. It may also be located in an airslide, or even in a product-loaded air stream. The installation of the sampling device takes only half a shift, using pneumatic transport from the sampler to the CEOPS unit via a hose with a quick connection coupling. Details of this sampling device are shown in Figure 2.

The particle size laser is installed in the CEOPS cabinet. The particle measurement range is from 0.1 µm – 1500 µm. Four measurements of the collected sample are taken per second.

The design of the CEOPS connects up to three sampling points. The samples are taken one after the other, transported to the CEOPS and then measured in series. The schematic setup and typical measurement results are depicted in Figures 3 and 4. The distance between the sampler and the CEOPS control system can be up to 50 m. The CEOPS can therefore be connected to up to three grinding systems.

If the distance between the sampling points exceeds 50 m, the CEOPS cabinet can be equipped with rollers for easy transportation between the sampling points, as shown in Figure 5. The disconnection and reconnection of the pneumatic transport hose to the sampling device take less than 10 min.

Interfaces to all major control system networks are provided. The CEOPS system can therefore be integrated into the existing operator control system.

CEMTEC has one system available for leasing, with a purchase option after the testing period, so that customers can experience the positive effects of CEOPS in their plants.

Operating resultsThe operational results of CEOPS’ increasing references in the cement industry (Leube Zement, W&P Zement, Cemex Poland) will be presented in future articles. Figure 5. Details of the CEOPS measuring unit.

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A FIRST FOR BORNEO

Cyrus Wiecko, Christian Pfeiffer, Germany, reports on the successful handover of East Malaysia’s first integrated cement plant.

IntroductionIn May 2016, Christian Pfeiffer successfully handed over its first turnkey cement grinding plant in Malaysia to Cahya Mata Sarawak (CMS). The plant includes raw material handling and finished product storage silos, as well as a fully automated packing plant (Figure 1). The EPC

52 \

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contract, based on FIDIC regulations, was signed in May 2014. This project represented the first EPC project Christian Pfeiffer has undertaken in Malaysia. Work on the entire plant infrastructure was successfully carried out, from engineering, purchasing and logistics, to the execution of civil, steel, mechanical, commissioning, electrical, and automation work, as well as all local permit procedures.

Through the project, CMS aimed to increase its cement production using a reliable and energy-efficient grinding plant capable of delivering various cement types in bulk, big bags and 50 kg bags, in loose or palletised form, with or without pallets.

The new plant is located next to an existing rotary kiln line in Mambong, Kuching. The clinker produced is directly fed to the new mill from an existing clinker silo, avoiding the need to transport the clinker to the existing grinding plant in Pending, over 30 km away. Any additional clinker requirement for the Pending plant, which is located near the sea, can be imported. This then provides significant savings in the overall logistic costs.

Description of the new grinding plant At the heart of the plant is a two-compartment ball mill with a 4.8 m dia. and 15 m effective grinding length (Figure 2), equipped with a high-efficiency QDK 248-Z separator (Figure 3) designed to produce 150 tph cement with a fineness of 3500 cm²/g acc. Blaine. The mill is supported by slide shoe bearings and driven by a lateral drive unit consisting of a girth gear and two pinion gear box with a floating shaft and a 5600 kW main motor. The feed materials, comprising clinker, gypsum, and limestone, are dosed separately via weigh feeders, while flyash can be added directly to the separator using a bucket elevator. To ensure the most effective comminution, the ball mill is equipped with progressive lifting and classifying liners and filled with Allmax® grinding balls. The material flow from the first to the second compartment is regulated by a Christian Pfeiffer intermediate flow-control diaphragm in Monobloc® design, to ensure an ideal material level and particle size for fine grinding in the second compartment. The finely ground cement leaves the mill via a discharge diaphragm – also a Christian Pfeiffer Monobloc design – and fed to the separator circuit by a bucket elevator.

The Christian Pfeiffer QDK 248-Z cross-flow separator has a very high separating efficiency and low bypass, easily reaching the required cement fineness using low recirculation rates. Separation of the ground cement is achieved using a high-efficiency, low-energy bag filter Figure 3. Christian Pfeiffer QDK 248-Z separator.

Figure 2. Christian Pfeiffer 4.8 m dia. x 15 m ball mill.

Figure 1. Draft layout of the new cement grinding plant for Cahya Mata Sarawak.

Cement Plants of the Future / 55World Cement

application with minimum dust content (below 10 mg/Nm³) remaining in the clean gas. The plant therefore easily meets the requirements of the local authority and the customer’s demand for a modern, eco-friendly plant. By using a continuous online monitoring system, which is directly linked to the government environmental control department, the appropriate verification is conducted.

The cement produced is stored in two interchangeable 10 000 t silos, one mono and the other duo-cell, thus allowing the production and storage of three different types of cement. Each silo is equipped with two bulk loading devices for conventional silo truck loading. Cement for the adjacent packing plant is transported via air slides and a bucket elevator. There a rotary packer, performing at a speed of 3000 bags/hr, can fill big-bags or cement paper bags. The single packed cement bags can either be directly loaded onto trucks or transferred to a palletiser. This fully automated palletising system is designed for both pallet and palletless operation.

Project realisation During the engineering and design phase, knowledge from multiple areas was brought together to ensure the effi cient selection and purchasing of imported equipment, as well as timely delivery. A particularly signifi cant challenge was posed by the transportation of the big 4.8 m dia. x 15 m length mill shell from Europe to Malaysia. Among other things, a pedestrian bridge had to be lifted and various power cables had to be cut to allow the low-loaders to reach the project site. This task was accomplished without any problems.

During the plant design phase, particular attention was given to creating a maintenance-friendly concept that allowed good accessibility to the drives using platforms and hoists. Other engineering services, such as static calculations of buildings, foundation plans, structural steel drawings, or the design of cables, were outsourced to longtime engineering partners and successfully carried out under the supervision of, and in cooperation with, Christian Pfeiffer as the general contractor.

The tropical climate on the island of Borneo confronted the company with the challenge of working under unpredictable conditions and with unknown local subcontractors. Consistently heavy rain during monsoon season hindered the excavation works for the building foundations, while persistent high temperatures and high humidity put considerable stress on both humans and machines. The location of the site also necessitated the shipment of some materials and machinery from

West Malaysia, as various items were unavailable locally.

Nonetheless, due to good cooperation with the local subcontractors, all requirements were met to finish each section. Thanks to good quality structural steel fabrication and fast erection, the preconditions for the following installation of peripheral equipment around the core components were completed before the next big tasks of cable termination, medium voltage, automation, and infrastructure, including road work, began. The connection of the medium voltage switch gear was done to the customer’s existing network.

By the end of December 2015, after nearly 18 months with the ongoing support of the customer and close cooperation of both parties, the first silo was filled with high-quality cement, allowing CMS to sell the finished product. During the following performance test, which took place over 4 x 20 hr, Christian Pfeiffer was able to achieve all contractually guaranteed values. The whole plant, from existing clinker silo discharge to the complete grinding plant, cement transport to silos, bulk loading, packing plant, and palletising system, performs with a power consumption of 39 kWh/t at a Blaine fineness of 3500 cm²/g.

With further process optimisation, the new grinding plant proved to be capable of reaching throughput rates above 160 tph at a Blaine fi neness of 3500 cm²/g. During the offi cial handing over ceremony in November 2016, CMS Group Managing Director, Dato’ Richard Curtis, expressed his satisfaction: “This third plant will increase CMSB’s total annual rated cement production capacity by almost 60%, to 2.75 million t, well above current local demand of around 1.7 – 1.8 million t. This will enable CMS to meet growing cement demand in Sarawak, including that from upcoming big projects, such as the Baleh dam and the Pan Borneo highway, to have signifi cant reserve production capacity to materially reduce the risk of supply disruptions, to extend our supply into nearby export markets, as well as to produce more than one type of cement.”

Figure 4. Bird’s eye view of the new CMS grinding plant.

RemoteService

Vibration

Torque

Process Signals

Predictive Failure Detection

DALOG Torque Monitoring System D-TMS

Proactive Failure Prevention

DALOG Condition Monitoring System D-CMS

Performance OptimizationDALOG Process Monitoring System D-PMS

Online Condition MonitoringPlant Protection Concept

58 \

PREDICTING THE FUTURE

Christoph Muschaweck, DALOG, Germany,Christoph Muschaweck, DALOG, Germany, introduces the plant protection concept: online condition monitoring for the cement plant of the future.

/ 59

IntroductionPreventing breakdowns is good but the main goal must be avoiding machinery failures from the beginning. This has been DALOG’s aim for almost two decades. A positive outcome of production can only be assured through an interconnected monitoring solution that covers the full value chain of the cement production process.

The foundation for predictive and proactive maintenanceCreating safe islands in the plants by using acceleration and temperature sensors to monitor the most critical assets allows gear and bearing failures to be predicted before they end in a catastrophic breakdown. A tooth failure on a gear can be detected before it breaks off and turns into a loose cannon within the gearbox. A bearing that is starting to pit can be ordered in time. Statistical models even allow for the prediction of the remaining lifetime of a machine component. In general, failures are detected at an early stage, which allows time to act and plan. Plants benefit from fewer unplanned stoppages and a minimisation of secondary damages. The next logical goal is to increase the time between failures, by optimising operational stability. The torque measurement on rotating shafts has shown to precisely measure the real load on the machine and a high-frequency measurement shows peaks that are not visible in the motor power. Consequently, it is a valuable tool to evaluate operational stability and to detect dangerous overloads on the machine. This is especially important for machines with a high dynamic process, such as vertical roller mills and roller presses, where operational instability can often be related to issues in the grinding elements of the process, such as an improper feed. For a root cause analysis of the process, the online condition monitoring system needs to be able to communicate with the PLC to receive parameters, including feed rate, pressures, and motor power. Sending alarms and trends to the DCS helps to integrate the operators in the project, which gives them the necessary information to take the appropriate measures to prevent machine failure or instability. One of the big challenges for the cement industry in its transition towards a digital plant will be the standardisation of communication protocols. OEM proprietary protocols dominate cement plants and, given that this situation


will not change soon, the DALOG condition monitoring system supports most of the fieldbus protocols to establish bi-directional communication with the PLC. The key elements preventing failure in the future are real load measurements using a torque sensor, the data exchange (process and condition) between the condition monitoring system and machine control, and the integration to the operator.

Online data acquisition for all machines The industry has made great progress with its maintenance strategies in recent years. Failure Mode and Effects Analysis (FMEA) is a standard tool used to evaluate risks. Many of the most critical machines, including mills and kilns, are equipped with an online condition monitoring system and so are respectively covered by the predictive maintenance strategy. Nevertheless, less complex and smaller equipment, such as fans, conveyors, or bucket elevators, often fall through the net, despite their clear impact on production. The maintenance strategy for those machines in today’s plants are either run to breakdown, preventitive, or condition-based using temporal measurements of the equipment.

For all of these, the initial investment is very low, but the ongoing operational costs are soaring. The run-to-failure strategy bears a multitude of risks and will cause unplanned stoppages and production loss. Preventive maintenance reduces the risk, but relies solely on lifetime estimations or manual inspections to schedule maintenance intervals. This either results in changing the machine parts too early or too late, higher spare part investment or production loss. Condition-based maintenance intervals can be achieved using mobile measurements. Yet the quality and reliability of analysis with mobile equipment is very varied. They are time consuming and must be carried out by trained personal that need to keep to a rigid schedule in taking those measurements. Risks involve selecting a suboptimal measurement position, not considering different machinery production situations at the time of the reading, or, in the worst cases, not taking the measurement at all. Trend analysis and process correlation is, in the best case, suboptimal.

The cement plant of the future will rely solely on a predictive and proactive maintenance strategy, which bases its decisions on data from online condition monitoring systems. While reducing time consuming field work, the plant can count on more precise measurements and a higher data density, increasing the reliability of predictions and consequently the availability of the plant.

New challenges for maintenance As the data density increases and analysis algorithms improve, what about the typical tasks for the

Effects of different strategies on overall performance.

Typical failure progression curve.

Control over a production step: typical monitoring tasks in the grinding process.

Value chain optimisation: focusing on the full value chain to control the outcome.

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maintenance team? While it is possible to measure the impacts of tropical rainfall on the feed of a vertical roller mill in a cement plant in the Philippines, or to detect the effects of sand (silica) on the operational stability of a roller press in the Midwest, integrating all of the external influences into an algorithm that could replace the judgement of a trained expert remains a huge task. On the other hand, as reliability increases and field work decreases, more time and effort will be spent on performance optimisation. The collected data will be used to build the foundation to plan, carry out, and measure the outcomes of such initiatives.

Experienced vibration analysis, maintenance, and process experts from DALOG, are already guiding many plants to interpret the data and optimise their performance.

A holistic approachHow can online condition monitoring go even further and support a company-wide strategy? One definition of strategy is a high-level plan to achieve one or more goals under conditions of uncertainty. It is clear that online condition monitoring continuously provides information on maintenance to eliminate uncertainty. But why stop there?

The DALOG online condition monitoring solution acquires data in high resolution to evaluate machine condition, operational stability and process parameters that helps to evaluate overall performance. The latest software generation, DALOG BusyBee, calculates key performance indicators and statistics that are visualised in customisable dashboards. It is possible to display statistics about machine availability, energy consumption, and operational stability, among others.

Access to the data is also not limited locally to plant facilities. An encrypted connection to the cloud permits access to the data worldwide from a laptop, smartphone, or tablet. This allows regional managers and headquarters to gain insight into the performance and condition of the cement plants in a region or country. Production strategies within the organisation as a whole will therefore be exposed to less uncertainty.

Looking backDALOG was founded in 1998. Back then, it was state of the art to equip the monitoring system with a GSM module to dial up and establish a 9.6 kBit/sec. connection. Few people back then could have imagined that today most plants would have access to the internet 100 000 times faster (1 Gbit/sec.). I would not dare to make a prediction for the technology that will exist in 20 years, but I can say what is possible today. The DALOG Plant Protection Concept is a bottom-up approach where, on the lowest layer, data is collected and stored on the cloud. The massive amount of data is processed to be used by different stakeholders within the same organisation. The maintenance team can work with precise failure analyses and can plan maintenance intervals based on machine conditions and proactively work on increasing the time between machine failures. The production team gains statistics and models for production planning. The plant manager can evaluate overall plant performance comfortably from his smartphone. In the end, online condition monitoring will build the foundation for a seamless integration of data-driven decision making within the whole organisation.

Worldwide performance overview: cloud access eliminates uncertainties.

DALOG commissioning at a vertical roller mill.

/ 63

Perry Zalevsky, OSIsoft,

USA, discusses how the discusses how the

facility of the future can facility of the future can

help cement manufacturers help cement manufacturers

to move forward.to move forward.

IntroductionCement has come a long way since the Romans used it to build the foundation of an empire over 2000 years ago, but many cement manufacturers are missing out on critical insights and new developments that could improve their productivity and/or save millions of dollars. Modern cement in 2016 represented a US$394 billion industry, producing an estimated 4.1 billion tpy of cement.

While cement consumption has increased, the use of big data and corresponding technology has lagged behind. Even small, data-driven adjustments can equate to millions of dollars in savings. Adoption, however, will not happen overnight; it is important that cement manufacturers proceed with appropriate caution. If manufacturers lay the right groundwork, the connected factory of the future will emerge as an integral part of the production and delivery of cement – and it will directly affect the bottom line.

The connected facility of the future will require manufacturing intelligence through a steady stream of data, in order to gain real-time insight into equipment and production. From quarry to crushing, transport to kiln and, ultimately, storage and delivery, cement manufacturers will use that data to optimise every asset along the entire process to ensure utmost profi tability. For example, by visualising this data in a single, coordinated view, manufacturers can reduce waste and identify maintenance needs in order to implement predictive, condition-based maintenance strategies to optimise and extend the life of expensive assets.

PICKING UP GOOD

CONNECTIONS


Cementing automation strategiesWhat is the ultimate ‘cement facility of the future?’ The answer depends on who you are. Some cement manufacturers collect operational data but primarily use it to monitor ongoing operations, i.e. are my kilns at the temperature they should be? You can call them collectors: they have invested in technology and leverage data in a day-to-day manner.

One level up from that are what you could call optimisers, i.e. companies that sift through operational data to reduce energy usage or improve productivity. Some more advanced ones also leverage this data for condition-based maintenance. Approximately 5%

of potential production time is lost annually due to unplanned downtime, according to industry fi gures. That 5%, however, represents US$20 billion in losses. Avoiding even a sliver of that downtime can be signifi cant.

But that is not the end: data from optimisation efforts can also be linked to enterprise applications or sales data to improve fi nancial viability. Some of these companies at the leading edge of the spear are also beginning to look at IoT (Internet of Things) technologies, i.e. data from sensors or facilities systems, such as HVAC or lighting that does not go through SCADA or control systems. Combining these sources of data can potentially give manufacturers a more comprehensive insight into their enterprises. Call these companies ‘IT-OT’ companies or transformers. (Admittedly, few have gone to these lengths yet.) At the other end of the spectrum, there are manufacturers that look at any investments in technology or analysis as money down the drain.

Case study: CemexCemex is the second largest building materials company in the world and a leading producer of cement. It provides a compelling example of a transformer. With over US$15 billion per year in revenue, Cemex is present in 50 countries and has a total of 71 production sites. With a goal of reducing total cost of ownership of plant assets, Cemex launched a programme to democratise data. That is, it invested in technology to make it easier to share, examine, and analyse data from its production plants, eliminating silos between different sources of data, as well as making access easier, so that any department could begin to study production data, without having to necessarily wait for assistance from IT or third-party consultants. Starting with one plant, Cemex began the process of standardising policies and procedures before moving the data to the transactional systems. Cemex relied on the OSIsoft PI system integrator and asset framework to create a standard practice to analyse process and asset information.

The initiative has helped Cemex drive towards a number of goals. One of the more interesting benefi ts, however, has come in how reports and data management have been streamlined. Before, gathering and preparing data for reports from all of Cemex’s plants could take 744 hours, according to Rodrigo Quintero, Director of Enterprise Risk Management at Cemex. The process now takes 5 min. because operational data is automatically shaped, cleaned, and delivered to other applications through the software stack. Human intervention is not necessary for most of these data tasks. Ultimately, the Cemex project expanded and data was democratised across the organisation.

Now, Cemex measures equipment by size and measure variation and is seeing a diminishing trend of variation, as well as improved accuracy and reliability of assets. Overall, it reduced the total cost of ownership of the previous system by US$800 000/yr and achieved calculated return on investment within six months.

Data from different devices is captured and brought into single screen views so technicians can monitor production, energy consumption, or other values.

Technicians viewing real-time process data.

Traditionally, screen views of operations were only delivered to engineers. Increasingly, screens with less engineering detail, and more detail about weather or pricing, are being generated for executives, sales and other employees.

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CEMENT


Case study: Ultratech Ultratech is the eighth largest cement provider in the world and is part of the Aditya Birla Group. It produces 52 million tpy of cement across 13 plant locations. Its goal was to bring data together into one platform and monitor product quality and asset performance in real time. After implementing over 100 000 sensor tags on equipment using the OSIsoft PI System, the company had access to real-time boiler process information and turbine health, which allowed it to predict potential process or quality issues, and minimise unplanned equipment outages.

For example, when data was analysed, Ultratech discovered that its spray lubricant consumption was too high. This lubricant was being automatically sprayed on girth gears. Ultratech made the adjustment to optimise the lubricant application and patterns based on equipment on/off times. This small adjustment resulted in reduced consumption and cost containment, which ultimately led to increased product quality.

Five steps to digital transformationAgain, digital transformation will not happen overnight. Automation technology and strategies are both a large undertaking and capital expenditure, and it is important take a metered approach in order to extract value in the early stages of any project. Here are the fi ve rules of the road.

Start smallOften, companies overreach when implementing new technologies, but realising immediate value is possible by starting with a small, but replicable, approach. For example, start with one plant or one particular type of asset and fi ne tune the parameters, data, and goals, before rolling it out to the broader organisation. Often, predictive analytics is a sound fi rst step, in part because of the potential costs savings. Condition-based or predictive maintenance can also be rolled out and tested alongside traditional reactive or scheduled maintenance. Risks are low. Like Cemex, manufacturers can also isolate their experiments to a single facility as a starting point.

Create the right contextWhen implementing technology strategy, it is easy for manufacturers to get mired in an onslaught of data. Establish goals in areas where real-time automation can make the biggest difference in the health of the organisation. For cement manufacturers, it is often most important to monitor kilns, furnaces, and transportation, as well as any other high-value equipment in realtime. Real-time data will help enable condition-based maintenance strategies, so manufacturers can simultaneously decrease equipment downtime and prevent catastrophic failures Not only will this optimise performance, it will decrease maintenance costs on the assets that matter the most.

Make appropriate adjustmentsAs with any project, automation will never be perfect the fi rst time. Just as real-time data is always changing, projects should also be a dynamic process. By consistently re-evaluating goals and making the right adjustments, manufacturers can correct course to ensure return on the investment.

Democratise and expandThe ultimate goal of any automation project is to democratise data into the hands of users across the organisation. When every team member is able to turn data into actionable insights, visibility is increased, so every process can be optimised to become more effi cient, effective, and profi table.

Think people, process, and technologySuccessful technology projects are rarely only about technology. People within an organisation should also be considered, as well as the business process and the technology. Generally, one needs all three to be aligned to enable meaningful change and improvements.

ConclusionThe last mile is the hardest, so start small, gain experience, get some success, and expand it gradually. Getting accurate, real-time data into the hands of decision makers across a cement company will smooth the path into the future.

User interface is one of the big areas of research in this fi eld. Companies are experimenting with colour and other signals to indicate signifi cant issues, without causing information overload.

A utility control room. Data streams can include power production, demand forecasts, power pricing trends, and potential maintenance issues.

SCANNINGSUCCESS

FOR

IntroductionOnce considered futuristic, 3D scanning and modelling is swiftly becoming the status quo in the cement industry. Companies that have taken a leap of faith by implementing this technology have found it to be pivotal in minimising risk and maximising profi ts when undertaking challenging plant projects. This article was

written to give a fundamental understanding of this technology to cement plant executives, who were previously unconvinced that it was relevant to their world. The evidence will make the value of this technology clear. For the cement industry, the future is now.

“I have been building cement plants for over 40 years, and in my mind, no other

LISA NEWHOUSE, PENTA

ENGINEERING CORP., USA,

EXPLAINS HOW TO USE 3D

SCANNING AND MODELLING

TECHNOLOGY FOR DESIGN

AND BUILDING SUCCESS.

/ 67


innovation has been more signifi cant in minimising errors in plant improvement projects than 3D scanning and modelling,”says Frank Benavides, CEO of PENTA Engineering Corp.

Choosing to scanWhether it is routine plant maintenance, or an upgrade project, performing 3D site scans before design begins will ensure the job is completed in the most accurate manner possible.

3D scanning uses advanced laser measurement technology to obtain dimensional values at many thousands of points per second. Each point will have an X, Y, and Z value. This data is commonly referred to as a ‘point cloud’, which provides a 3D shape, or visualisation, of the features being measured. PENTA integrates this information via surveyed benchmarks to create a point cloud that is connected to a site’s real world coordinate system.

Ask yourself these questions if you are still wondering how this technology applies:

When going to the job site to take field measurements, how many times do you forget to take one specific measurement?

How many times are you unable to get a measurement? (E.g. you need a man-lift to get a measurement and one is not available.)

With 3D scanning, a permanent 3D image is created that can be used to take measurements, as needed, for every project down the road. When importing this information into 3D software, such as Solid Works, Inventor, or Revit, every detail in a real-world state can be seen, as a new facility is laid out or an existing one modifi ed. Employee safety and effi ciency is taken to new levels with this technology. Additionally, this accurate information will be shared with project managers, plant engineers, construction managers, site engineers, and the like, to enhance communication between the teams that are working to complete a project.

Depending on the purpose of the scan, the amount of data collected can be varied. For example, when scanning an underground mine with limited light, there is no reason to utilise colour scans and to follow up those scans with photographs. Each scan takes only about two minutes. Conversely, when scanning above ground with plenty of light, colour scans with photographs are handy for measuring between points. A comprehensive colour scan takes about fi ve minutes per scan. The last type of scan with photographs usually takes 10 – 15 min. per scan, and collects so many points of data that most computers cannot handle it. These hyper-detailed scans are so accurate, they are also used in the fi eld of forensics.

Needless to say, there are a variety of scanners to facilitate different types of scans. Some scanners are accurate to within 2 mm when scanning within 130 m, and are used mostly inside buildings. Other scanners

In OKC, 3D scans helped PENTA visualise potential interferences compared to just using 2D drawings.

These OKC 3D scans maximised return on investment, as PENTA was able to avoid interferences and potential rework.

PENTA scanned existing ductwork in a confi dential cement plant and created fabrication drawings for the client.

are accurate up to 1000 m. These scanners have their drawbacks in that they cannot scan any object within 2 m. They are the preferred scanner for large fi eld areas, but not inside buildings. Depending on the job, PENTA will tailor the scans to suit the needs of each project for each individual facility. An investment in 3D scanning technology will therefore vary widely and will refl ect a project’s customised scope.

Whether the project is placing a hoist beam above a piece of equipment, modifying hoppers due to plugging, or a new installation, 3D scanning is necessary in order to avoid interference with existing obstacles. Improved constructability is achieved with 3D scanning, and this is signifi cant when most cement companies are striving to reduce risk, maximise profi ts, and eliminate rework on projects.

3D scanning also provides clients with ‘as built’ drawings for greenfi eld projects. The goal is for clients to be able to visualise their cement plant using this technology before the project even begins. These high-tech visual aids mean that there are no surprises during the entire process. It is a win/win situation, benefi ting both the client and the design/build company.

Avoiding interference in OklahomaPENTA completed an EPC installation on top of an existing four pack of silos for a cement terminal in Oklahoma City, Oklahoma, USA. There were multiple pipelines, steel structures, conduits, and existing

equipment on top of the silos. PENTA’s task was to build a new steel platform and walkway for an air gravity conveyor above all of the existing objects. Additionally, the columns for the new steel platform had to be placed in between all of the existing obstacles. With the use of advanced 3D scanning techniques, PENTA was able to miss every obstacle with no interference.

“As a design/build company, 3D scanning allows us to identify interferences with existing equipment, utilities, supporting structures, etc. on the computer, and to make design and layout adjustments prior to actual construction. This eliminates costly revisions in the fi eld, and helps to avoid construction delays on a project,” said Gary Gifford, Vice President of Construction Services for PENTA Industrial.

Providing underground aidPENTA used 3D scanning technology for a project in an abandoned underground limestone quarry. The client is currently in the process of converting the space into offi ces and warehouses. PENTA scanned the inside and the outside of the mine and was able to use the data in the initial phases of the project to help determine how to excavate the mine’s opening for truck traffi c.

The data provided useful insights for ground control by mapping all the joints and fractures in the roof. PENTA determined the appropriate method for roof stabilisation by analysing the 3D data collected. The 3D scanning data also accurately depicted the entries and

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pillars, which were not shown using other surveying methods. Over time, as this client builds out more of the mine, the initial 3D scans will continue to deliver useful data.

The learning curveThe main problem for most companies using this technology is that they lack the necessary computing power. According to Brett Settles, PENTA’s 3D scanning specialist and engineer, companies need to use powerful computers specifi cally designed to meet the needs of the high data transfer and graphic demand involved. This is where the cost benefi t needs to be determined and the scope decided upon. PENTA provides clients with an .RCP (ReCap) fi le, which can be read with an Autodesk ReCap. (This is free for the non-pro version.) This freeware limits you to viewing the scans and taking measurements. For a maintenance manager or plant engineer, these limited uses for the data might be suffi cient. Yet, if you the plan is to import this data into 3D CAD software, processing speed and hard-drive capacity need to be taken into consideration.

“A recent scan of a cement plant took 1000 scans, resulting in a 249 GB scan project and a grand total

of 335 GB collected. Each scan has anywhere from 200 MB to 1 GB of information. The scans must be stitched together, and the more scans that are stitched together, the more computing power companies need in order to utilise the information properly,” explained Settles.

One of the most overlooked technologies in the cement industry is 3D scanning, due to a general lack of understanding as to how much value a scan can bring to a project. The benefi ts can be realised in many different ways. The most obvious benefi t is the ability to quickly and accurately measure many objects in one go. Secondary benefi ts include the following:

Fewer site trips, which enhances employee and contractor efficiency and safety, by reducing time spent in the field.

Readily available data, which can be used to approach new projects in the future.

Quicker project mobilisation (for all future projects). Interference detection with new proposed

engineering projects. Accurate visualisation and the reconciliation of

improvements and minor site changes that may not have been recorded or documented during plant operation.

Having an accurate scan of a facility and/or project can, in some cases, highlight issues that may not have surfaced until too late in regards to saving costs on delivery, mobilisation, and labour. Being able to preconceive the optimal handling of logistics, or knowing that a large piece of equipment will not fi t before that ‘oops’ moment in the fi eld, can reduce costs drastically. It is commonplace for cement plant construction projects to face obstacles like these. The true purpose of 3D scanning is to resolve these issues before a client’s contractors run into them. Saving money by skipping these scans is akin to tripping over dollars to pick up pennies. If the goal is to maximise return on investment and minimise risk when tackling plant projects, then 3D scanning is the golden ticket.

Conclusion: selecting the right partner“Unfortunately, I hear horror stories all the time. Just the other day, a client told me he had one of his company’s sites scanned, spending US$50 000+, and then realised no benefi ts from the scans. He said the scanning company didn’t know how to use the data in a way he could benefi t,” said Settles.

Scanning companies are a dime a dozen these days. It is important to select a well-established company that commands a thorough understanding of the relevant industry niche, and possesses extensive experience putting this technology to work. Essentially, you need a partner who can guide you through the entire process. This is the only way to ensure you are prepared with the knowledge and the right equipment to make use of the scans once they are delivered.

3D scanning data is used over time to benefi t the ongoing development of Rock City (an underground limestone mine converted into a cold storage facility) in Valmeyer, Illinois.

Example of complete 3D scans of an aboveground plant in northeastern US.

NICHOLAS HOLST, FLSMIDTH OPERATION & MAINTENANCE, DENMARK, CONSIDERS HOW

NEXT-GENERATION TECHNOLOGY PLATFORMS AND UPSKILLING PLANT STAFF CAN HELP TODAY’S CEMENT PRODUCERS ACHIEVE A

COMPETITIVE ADVANTAGE.

IntroductionWhen opportunities for investment in new equipment are limited, cement producers have instead directed much of their investment towards their current assets. They have optimised equipment and machinery through dedicated operations and maintenance programmes aimed at prolonging the operational lifetime of equipment. For many, this has been a worthwhile investment that produces positive results. Now, however, as owners are

PRODUCTIVITY G O E S D I G I T A L

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looking to maximise investments even more, there is a need to look beyond the productivity of specifi c equipment, towards a holistic view of plant productivity by upskilling plant management and personnel using FLSmidth O&M’s Technical Centre Solution. This view can unlock new areas of competitive advantage, as the full potential of equipment performance is paired with the full potential of plant staff’s abilities and effi ciency.

Towards operational excellencePlant productivity in today’s competitive environment requires an aspiration towards operational excellence. This means continuously improving and preserving all critical activities infl uencing plant performance, which requires a wide range of technical expertise, in addition to a structured and systematic approach. Many cement plants today, however, have suffered from a lack of access to suffi ciently skilled staff, which in turn has made it diffi cult to structure their approach.

Furthermore, one could challenge the cement industry in that it has been slow to adopt the practices used by more technically advanced industries, such as automotive, aerospace, and food manufacturing. In these industries, stiff competition and rapid technological advances forced manufacturers to improve the productivity of their operations. For the leading players, however, this was just the start. They stepped up their game by pioneering the use of internet-based communications and powerful data processing capabilities. If cement producers are to continue meeting the needs of an increasingly demanding market, it is vital that they adopt such practices within their normal daily procedures.

Figure 2. The dashboard is designed with colour codes to illustrate the turnover rates of items in stock. Dynamic fi lters, shown on the right, enable users to answer questions specifi cally related to their requirements. Labels and values are removed or masked for confi dentiality.

Figure 3. Owners need a simple way to see key performance data from multiple plants.

Figure 1. FLSmidth’s Online Productivity Centre combines three critical technologies for achieving operational excellence.

O&M Productivity Platforms Key to driving cement producers’ operational excellence are three broad areas of technologies: real-time monitoring, business intelligence, and performance management. Rather than just seeing each as a separate entity, it is the combination of these technologies that provides the true potential: the O&M Productivity Platform.

Real-time monitoring of plant equipment is the starting point. This involves monitoring everything within the plant’s control systems, so that operators can use real-time data on any aspect of plant performance to provide appropriate technical diagnostics. By utilising internet-based technologies and integrated IT systems, monitoring can take place through remote hook-ups; operators do not need to be located onsite.

While real-time data from the plant’s control system is useful for online technical diagnostics, data from various other IT systems also contains valuable information that can lead to signifi cant productivity improvements. Data from the fi nance, quality, production, downtime, and asset management systems all contain valuable information that is often time consuming to collect and process. Automating the collection and processing of data from the plant’s IT systems and delivering timely insight through reports and dashboards are critical to optimising plant performance.

Creating value from dataThe key to using data to improve productivity is to spend less time acquiring data and more time analysing it for proactive planning and the improvement of operations.

This is where the Business Intelligence Platform comes into play, enabling operators to automatically extract critical business information and plan for increased operations effi ciency. Using advanced analytics, the Business Intelligence Platform can overlay data from multiple sources to reveal unknown causes of low productivity.

Getting automated reports from the Business Intelligence Platform is the fi rst step, but to create value from the insight, action is a must. The Performance Management Platform is designed specifi cally to plan and execute these actions, while documenting the entire process for future reference when similar actions are required.

Figure 2 shows an example from the Business Intelligence Platform where turnover rates for inventories across several storerooms are automatically reported. The dashboard identifi es potentials for optimising net working capital, tied up as inventory, representing signifi cant business value. Involving the relevant stakeholders and giving them such a dashboard allows an action plan to be made based on facts. Finally, the Performance Management Platform is used to drive


the execution of this, which allows everyone to leverage the experience and insight in the future.

The power of insightApart from systematic improvements, an important benefi t of the Productivity Platforms is that they empower plant managers and equipment operators to understand equipment behaviour. Armed with this insight, they can make the necessary operational improvements.

Insight also extends beyond just individual equipment. Many owners have several cement plants, and managing the performance of multiple cement plants further amplifi es the need for data crunching. Inevitably, therefore, reporting becomes even more complex. For management to understand the business impact of their operations, a holistic platform needs to bring together all the relevant key performance indicators (KPIs) and benchmarks into one concise overview.

Making performance more predictableWith its Online Productivity Centre (OPC), FLSmidth combines real-time monitoring, the Business Intelligence Platform, and the Performance Management Platform into one integrated productivity platform. Through OPC, FLSmidth provides a comprehensive range of support for all areas of cement plant operation, from quarry management and clinker production to cement grinding, packing, and dispatch. It includes remote support and monitoring, systems implementation, training, and permanent support from FLSmidth’s global organisation.

OPC provides access to experts within all disciplines of cement plant operations at a far lower cost than it would take for a plant to instigate a similar set-up. The actual agreement is based on mutually selected production goals and predefi ned targets, in which FLSmidth specialists monitor cement plant operations and provide assistance remotely or via pre-arranged visits.

But KPIs and performance targets are not only based on hard numbers, such as operational performance measures and cost savings. They are also based on outcomes, such as the completion of specifi c training programmes and attainment of certifi cations. This underpins an important objective of the offering: to develop operating staff’s competencies.

Online support in action One plant that is making use of the Online Productivity Centre is the Zliten cement plant in Libya, owned by Arab Union Contracting Co. (AUCC). FLSmidth has cooperated with AUCC since 2008, when it supplied the fi rst production line. The second production line was completed and commissioned in 2010. The daily production of both lines is 9200 tpd of clinker.

Since 2015, FLSmidth has provided a team of dedicated specialists, through its Online Productivity Centre, to support the local contractor with every aspect of the daily operation and maintenance. This ensures that the plant has full access to continuous assistance from FLSmidth Group experts globally.

Conclusion: integrating advanced technologies The FLSmidth Productivity Platforms improved staff utilisation is helping early adopters to take productivity to a new level. While such developments have already provided compelling advantages, there is more to come, as more advanced technologies are explored within the industry, including drones, augmented reality, the Internet of Things, and artifi cial intelligence. Those who can adapt to the changing market conditions by using advanced data analytics and new technologies as levers for improving productivity are likely to gain the greatest competitive advantage.

Figure 4. Based on a plant’s specifi c needs, FLSmidth’s Online Productivity Centre includes a combination of services provided remotely 24/7 and through plant visits by specialists.

IntroductionThere are various methods of increasing the CO2 credits and reducing the energy requirements of a cement plant.

The waste heat recovery system (WHR) creates electrical energy using the heat from waste gases, depending on the raw mix and process conditions of the clinker kiln line. This energy is free and can reduce the costs of the final product.

The combustion of alternative fuels (AF) also reduces variable costs, because these types of fuels are much cheaper than fossil fuels (heavy oil, coal, or petcoke). AF reduce CO2 emissions and could represent 80% of the needed consumption of a cement plant.

Renewable energy is also being increasingly used as back-up auxiliary energy. Wind and solar power plants are likely to be developed near cement plants and will further reduce the CO2 footprint of cement companies.

The clinker kiln line also allows for the elimination of dangerous waste, because the high temperature of the flame traps harmful molecules in the final product, reducing any potential future pollution.

On the electrical side, low consumption motors, frequency converters, and process optimisation are the most important vectors for energy efficiency. The additional investment cost is low, compared with the running cost for the complete life duration of the plant.

TWINTHE DIGITAL

PATRICK LOGEROT, SNEF GROUP, FRANCE, EXPLORES THE

FUTURE OF GREEN CEMENT PLANTS, WHICH RELY ON

DIGITALISATION TO REDUCE ENERGY REQUIREMENTS AND

INCREASE CO2 CREDITS, BY PROVIDING A CENTRALISED,

SHARED KNOWLEDGE OF THE EQUIPMENT USED.

ntroductionntroductiohere are various methods of increasing the COhere are various methods of increasing the CO22

redits and reducing the energy requirements of aredits and reducing the energy requirements of a

Renewable energy is also being increasingly Renewable energy is also being increasingly used as back-up auxiliary energy. Wind and solaused as back-up auxiliary energy. Wind and solapower plants are likely to be developed nearpower plants are likely to be developed near

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Modularity and standardisationToday, small modular cement grinding stations can be implemented anywhere in the world (including on the water) and moved near to spot markets. This reduces the fi nal transport cost of the cement.

This modularity and standardisation is also observed on the electrical side, through the use of preassembled supply. That is the case, for example, with electrical shelters that are already tested by the factory and are ready to be connected.

Standard engineering rules, along with predefined components and designs, allow a lego-style assembly of standard mechanical components, as well as the automatisation of assembly tasks. Industrial robots will be in widespread use in some factories to manufacture electrical cubicles, based on standard engineering and drawings.

This flexibility is also visible on the control side, with more and more distributed configuration, using field boxes very close to the process, or integrated subsystems that are able to communicate with each other. The Internet of Things is also being introduced to plants.

Engineering modular assets in a virtual plant This scalability begins at the engineering stage, and is now based on the handling of complete assets that integrate the different electrical, mechanical, or process aspects. This is also linked to a virtual reality model, including 3D visualisation, with all the required information and documentation. For revamping or upgrade projects, a 3D-laser tool allows basic 3D representations to be created or missing elements to be included in a project.

This model is moving towards a virtual cement plant, and also enables the simulation, planning, and execution of maintenance tasks, including the provision of required materials and personnel, and the determination of possible conflicts with other activities.

This allows simulation at the engineering phase, through the testing of what-if situations that would be difficult to test during commissioning. This is often the case in upgrades to existing plants, which aim to decrease the length of time that production must be stopped.

Solid shredded waste used by the Medgidia cement plant, Romania, to decrease energy costs.

Ready-to-connect shelter models are used to decrease the site works duration, or to meet the needs of harsh environmental conditions, such as quarries.

The powerless S-box allows for wireless, economic, and reliable data transmission of signals from isolated locations.

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This has been achieved using a common structural basis for all data across the entire plant. The completion of the whole project, including commissioning, is moving towards the concept of a digital twin. This enables a predictive and simulation approach that links the reaction of different parts of the plant within a global, efficiency-oriented model.

A future without cables? Is it possible to escape cabling contingencies? In some cases, Snef can provide an economic and feasible solution, especially for isolated auxiliary devices.

Snef has developed a box that connects information from various parts of a technical system and transmits it wirelessly to a central platform, avoiding any control cables. If needed, this box can be autonomous – without control cables or power cables. The system is powered through a battery with a ten year lifespan and remote load survey.

The box transmits wireless data and triggers leak alarms, making it possible to monitor specific equipment using a split core current transformer. This means impulsive energy counters, pump digital signals, analogue consumption, or filling rate data connected to the box at any location in the plant can be transmitted wirelessly.

The very low consumption is due to the low-frequency private network. This autonomy makes the plant immune to power cuts, while its radio network makes it independent from cellular networks and their disturbances.

The box is suited to the harsh environment of cement plants. It is designed to operate between -40˚C – +85˚C, and withstand challenging environments (dust, water, impacts).

There are a wide range of applications, for example for dispatch systems controlling the input-output flows of the plant. Wireless operation gives the opportunity to connect isolated sensors that are far away from any power source or concentrator, or even information from mobile devices, such as fork lifts in the packing plant.

Energy managementThe box can also collect different signals or counters that are linked with energy monitoring, or even avoid the unloaded running of long conveyors, by fixing a sensor at the entrance point of a conveyor, normally far from the corresponding motor, to interlock the running with the presence of materials, and reduce energy usage.

A standard control system, or SCADA, could also, as a first step, visualise basic information and help to save energy. Another way of improving this is to optimise the indoor and outdoor lighting by using presence detection, upgrading the equipment with LEDs, or managing the office temperature.

An energy audit can help the manager to use energy more efficiently. It is associated with incentives in some countries – the corresponding European Standard for this audit being EN 16247. An important consideration for a cement plant is knowing the status of the 500 – 1000 motors involved in the process. The Intelligent Motor Control Centres, linked with fieldbus to the control system, are built around an intelligent relay, which manages and monitors the motor, and other key process variables, such as the used power or the current of the low-voltage motor and other core data.

Detailed, real-time information is also available on medium voltage feeders and frequency converters, providing a comprehensive view of the plant. This enables the energy consumption of the plant to be managed with maximal efficiency.

ISO 50001 is a voluntary international standard intended to provide organisations with recognised frameworks for integrating energy performance

Medium voltage, pre-assembled cells, or intelligent MCC, gives a clear picture of the energy diagnostic and improvement capability of the cement plant.

Video survey, such as this 360˚ camera, can track and log different tasks, to secure the plant and provide automatic control and documented reports.

Cement Plants of the Future / 79World Cement

into their management practices. It requires energy management to be considered at the top level of the company, and follows the plan-do-check-act process for continuous improvement. This energy standard is becoming increasingly common in the industry.

Enhanced securityAccess to cement plants is often quite open because the loading and the unloading process is automated. Solutions are deployed using automatic recognition of the registration number of the vehicle, which then links to the corresponding ERP and invoicing system, weighting process, etc. Solutions can also extend this assistance by providing the real-time itinerary of the truck to its end customers.

However, additional measures are needed to increase human and plant security. Technology allows us to know, at any time, the number and names of persons in each predefined area thanks to geo-location and solutions that integrate security access based on fingerprint, RFID or vision technologies, such as the remote or automatic control of cameras to survey the plant. This survey can be also applied to detect robberies, material stock reserves, or even fires.

From field data to Big DataThe challenge is to collect data from the various sensors or non-process devices, and then compile it to produce an overall picture of the plant from all perspectives, from operation and maintenance, to operational performance.

The field data generated by the control system is integrated into the network, and then used on different platforms (tablets, PC, ultra-books), either in real time or as computed data. Alerts can be received by SMS, email, or voice mail.

The data is integrated, compiled, and can then be analysed. It is hoped that, in the future, analysis of this data will be used to deduce characteristics or patterns of damage from the sensor data, thereby arriving at smart data. Damage identification will also be further perfected and automated, enhancing the fields of predictive maintenance, and globally optimising the running time of the cement plant.

Making the job easierAnother aspect of data exchange, not linked to real-time data, is the e-documentation and the dematerialisation between companies that are working from a common data frame or documentation platform. Information is also available on different terminals, which allows the management of workflows, a body of structured documentation, and brings better reliability of data and information fluidity. This is often the beginning of a digital plant, even before the real-time aspects.

Making data access easier, readable, and focused on individual need avoids information overload.

This can be realised using augmented reality, consisting of adding real-time, digital information to the physical information found on a device. This provides a far greater amount of key information – much more than would be received through the physical perception of the elements alone.

The goal of all these opportunities is to clearly increase the quality of information and to use the analytical ability of computers for maintenance diagnostics or to help make decisions. This complements the artificial intelligence that has already improved kiln and mill optimisation systems. These aim to increase operational performance by reducing fuel consumption, producing softer burned lime and enabling more stable reactivity and stable residual CO2 (LOI). This kind of automatic pilot should decrease the quantity of operator stations and promote summary information.

Remote control and optimising plantsNew, web-based software that fully utilises SQL databases opens up new possibilities that were previously impossible. A corporate wide area network (WAN) can be used to combine sites, which all log data and are linked to a central server, from which reports from any of the sites can be generated.

Enhanced reality: additional information, such as the thermal monitoring of a motor, is overlaid onto the physical image of the object, allowing decisions to be made at a glance, as well as decreasing repair time.

Specialists can remotely access the real-time data to give effi cient and effective assistance, without needing to travel.


AD INDEX27 A TEC Group

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15 Bedeschiwww.bedeschi.com

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73 BME Serviceswww.bmecement.com

09 Cemengalwww.cemengal.com

56 + 57 DALOGwww.dalog.net

45 Digital Control Labwww.digitalcontrollab.com

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49 FLSmidth Ventomaticwww.fl smidthventomatic.com

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02 HEKOwww.heko.com

04 HOTAwww.hota.com.cn

33 Ibitek Groupwww.ibitek-group.com

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17 Kima Echzeitsystemewww.kimaE.de

OFC + 31 Loeschewww.loesche.com

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41 Peter und Lochnerpul-ingenieure.de

13 Scheuchwww.scheuch.com

23 thyssenkruppwww.thyssenkrupp-industrial-solutions.com

The PLCs can be put on the ethernet, along with all the servers on the same WAN, and everything can be controlled and maintained remotely. A technical centre, linked to a VPN gateway or servers, is theoretically able to start a cement plant, 5000 km away, and at the same time update the schedule of the relevant personnel. This allows for:

Remote visualisation of cement plants worldwide on a videowall.

Key performance indicators or remote MES functionalities on a central managing point.

Remote process analysis, by specialists in one location, of all analogue or digital values of a process line, with access to all the necessary historic views. This means fewer specialists travelling all over the world, and thus greater efficiency.

Remote assistance and maintenance services.

The cybersecurity aspects therefore have to be managed carefully, and represent a crucial aspect of the job.

Smart plant and community relationshipsThis connectivity revolution in smart plants has huge implications. The ‘Homo Numericus’ will be assisted or replaced by machines for analytical or repetitive tasks, and can concentrate on inductive thinking and the execution of goals in the non-digital world.

The disclosure of information also rewrites the balance of power in the factory by gathering together maintenance staff, operators, and IT teams. It is hoped that this new community will share, rather than own, the information, thereby building a collective intelligence towards an optimised and efficient cement plant, with a reduced environmental footprint.

FIVES IS COMMITTED TO THE PLANT OF THE FUTURE

www.fi vesgroup.com

FIVESTECH

+FIVESTEAM

FIVES’ EXPERTISE AND TECHNOLOGIES ARE RECOGNIZED by many major players all around the world. With an extensive experience in engineering and project management, Fives delivers solutions integrating the best available technologies in terms of performance and sustainability. To decrease the cement plant’s energy consumption and reduce its environmental footprint, Fives provides pioneering solutions that meet both today’s requirements and challenges of tomorrow.With patented technologies such as the FCB Horomill® and the FCB TSV™ Classifi er, Fives delivers optimized and effi cient grinding plants that produce high-quality cement, in fully automatic mode, at the lowest cost, with the utmost fl exibility. In the fi eld of pyro-process, Fives integrates the FCB Zero-NOx Preca, designed to maximize the use of alternative solid fuels, with no NOx production, and the TGT® Filter, that limits the plant’s emissions to the lowest levels. Read more on pp.38 – 42

Banff, Canada

Just one of the many environmental neighbors of KHD Humboldt Wedag

CLEANTECHNOLOGIES

For 160 years, KHD technologies have changed the way cement is manufactured, deploying real-world solutions

to ensure that the environments we operate in remain untouched and vistas like this intact.

To get more out of your plant, visit www.khd.comget more out of your plant.

From leaps made in energy-efficient pre-heater towers and modular

grinding systems to increasing the ability for burners and calciners

to utilize alternative fuels, KHD is continually creating new

opportunities to move the industry forward

in harmony with the environment.

KHD Innovations Help Plants Get More By Using Less

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ENTER A NEW DIMENSION – LOESCHE CCGpublications.worldcement.com/pdf/world-cement/2017/CPOTF/ptf17cp.pdf · The LOESCHE Compact Cement Grinding plant (CCG) plant – globally recognised