Pub Date : 2019-04-01DOI: 10.1109/CITCON.2019.8729099
J. Kline
One large international cement producer made an assessment of the common characteristics of their plants with the best technical performance. The best performance was defined as plants with consistently high uptimes as well as consistent product quality, low energy consumption, excellent environmental performance and low production costs. On further investigation it was seen that these plants also had the best safety records. The company then investigated further to determine what could be critical factors in this success across all technical platforms and linked closely to safety performance.It was found that the keys to safety excellence and technical performance could be summarized in three critical areas. First, a highly engaged plant management team with clearly stated and widely communicated objectives and with open and transparent communications at all levels. The second factor, was having robust work processes in the plant. The third factor was having highly competent personnel in the key positions critical to success. Reflection would indicate that these factors should not only give excellent technical results, but should also provide for a high regard for safety.
{"title":"Can Safety be the Master Measure?","authors":"J. Kline","doi":"10.1109/CITCON.2019.8729099","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729099","url":null,"abstract":"One large international cement producer made an assessment of the common characteristics of their plants with the best technical performance. The best performance was defined as plants with consistently high uptimes as well as consistent product quality, low energy consumption, excellent environmental performance and low production costs. On further investigation it was seen that these plants also had the best safety records. The company then investigated further to determine what could be critical factors in this success across all technical platforms and linked closely to safety performance.It was found that the keys to safety excellence and technical performance could be summarized in three critical areas. First, a highly engaged plant management team with clearly stated and widely communicated objectives and with open and transparent communications at all levels. The second factor, was having robust work processes in the plant. The third factor was having highly competent personnel in the key positions critical to success. Reflection would indicate that these factors should not only give excellent technical results, but should also provide for a high regard for safety.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"82 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115457196","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-04-01DOI: 10.1109/CITCON.2019.8729103
Sean Orchuk
Large motor trains installed in the cement industry are inexorably linked to critical processes and the failure of a unit may result in unplanned outages, deferred production, and substantial loss of revenue. Whether by error in protection, programming, installation, operation, or simply misfortune, the loss of critical equipment has far-reaching consequences for a cement installation and is often the cause of major changes in process or methodology. The desire to take rapid corrective action after a failure often leads to hurried investment, and this may fail to completely address the root causes. In this paper, a variety of characteristic motor failures and their contributing root-causes is analyzed so that a causative improvement system may be developed. This system can be applied before failure to assess the health and robustness of critical electrical equipment installed within a cement plant. By establishing a quantitative scorecard and comparing this to historical data, an early-warning system is derived which can be used to identify deficiencies in equipment and guide maintenance resources with the maximum return on investment.
{"title":"Parametric Motor Health System Lessons Learned Through Failure","authors":"Sean Orchuk","doi":"10.1109/CITCON.2019.8729103","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729103","url":null,"abstract":"Large motor trains installed in the cement industry are inexorably linked to critical processes and the failure of a unit may result in unplanned outages, deferred production, and substantial loss of revenue. Whether by error in protection, programming, installation, operation, or simply misfortune, the loss of critical equipment has far-reaching consequences for a cement installation and is often the cause of major changes in process or methodology. The desire to take rapid corrective action after a failure often leads to hurried investment, and this may fail to completely address the root causes. In this paper, a variety of characteristic motor failures and their contributing root-causes is analyzed so that a causative improvement system may be developed. This system can be applied before failure to assess the health and robustness of critical electrical equipment installed within a cement plant. By establishing a quantitative scorecard and comparing this to historical data, an early-warning system is derived which can be used to identify deficiencies in equipment and guide maintenance resources with the maximum return on investment.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"3 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122313350","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-04-01DOI: 10.1109/CITCON.2019.8729106
Xavier d’Hubert, Sébastien Borguet, Lâl Mandarin
Using various industrial cases this paper presents the potential effectiveness of the modern microgrid system to provide electricity bill reduction to energy intensive plants, depending on their location.The presented microgrid system is a 2 MWp PV and 2.26 MW/4.2 MWh mixed-technology battery storage, grid connected, which supplies a manufacturing facility and offices.A project being developed in Central America at a Cement grinding plant, with 5 MWp PV, 1 MW/4MWh hybrid flow battery storage, grid connected under the "electricity as a service" (PPA) scheme,How the Global Adjustment (demand charges) scheme of the Ontario grid is being solved with battery storage, even where electricity is cheap.Why technology such as flow batteries is relevant to the specifics of the Cement Industry.The importance of local regulations & legislations and the relationship with the local utilities emphasize the uniqueness of each project and the difficulty implementing them. On-going equipment cost reduction should nevertheless bring more projects on-line in the coming years.Cases studies of various projects applicable to the cement industry including a micro-grid project and flow batteries development will be presented.The objective is electricity bill reduction.
{"title":"Benefits of Micro-grids for the Cement & Mineral Industries","authors":"Xavier d’Hubert, Sébastien Borguet, Lâl Mandarin","doi":"10.1109/CITCON.2019.8729106","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729106","url":null,"abstract":"Using various industrial cases this paper presents the potential effectiveness of the modern microgrid system to provide electricity bill reduction to energy intensive plants, depending on their location.The presented microgrid system is a 2 MWp PV and 2.26 MW/4.2 MWh mixed-technology battery storage, grid connected, which supplies a manufacturing facility and offices.A project being developed in Central America at a Cement grinding plant, with 5 MWp PV, 1 MW/4MWh hybrid flow battery storage, grid connected under the \"electricity as a service\" (PPA) scheme,How the Global Adjustment (demand charges) scheme of the Ontario grid is being solved with battery storage, even where electricity is cheap.Why technology such as flow batteries is relevant to the specifics of the Cement Industry.The importance of local regulations & legislations and the relationship with the local utilities emphasize the uniqueness of each project and the difficulty implementing them. On-going equipment cost reduction should nevertheless bring more projects on-line in the coming years.Cases studies of various projects applicable to the cement industry including a micro-grid project and flow batteries development will be presented.The objective is electricity bill reduction.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"34 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131580155","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-04-01DOI: 10.1109/CITCON.2019.8729105
F. Mielli, Nicole Bulanda
The World Economic Forum predicts that digital transformation initiatives will lead to more than $320 billion of value for the mining and cement industries, a 610 million ton reduction in CO2 emissions, and 1,000 lives saved as worker safety improves.But no one is talking about the fact that most digital transformation initiatives fail before they’re fully implemented. The problem isn’t isolated either: a recent Gartner study showed that across all market segments, 85% of big data projects fail.How can a company ‘go digital’ safely?This paper will examine the main roadblocks encountered in digital transformation projects: From lack of holistic vision and clear definition of corporate digital strategy, to talent deficits, failure to plan for scalability, and internal resistance to change. We will share some simple ideas that work for our customers, provide information about ‘ready-to-implement’ technologies, and help construct a basic roadmap for implementing digital transformation projects.
{"title":"Digital Transformation: Why Projects Fail, Potential Best Practices and Successful Initiatives","authors":"F. Mielli, Nicole Bulanda","doi":"10.1109/CITCON.2019.8729105","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729105","url":null,"abstract":"The World Economic Forum predicts that digital transformation initiatives will lead to more than $320 billion of value for the mining and cement industries, a 610 million ton reduction in CO2 emissions, and 1,000 lives saved as worker safety improves.But no one is talking about the fact that most digital transformation initiatives fail before they’re fully implemented. The problem isn’t isolated either: a recent Gartner study showed that across all market segments, 85% of big data projects fail.How can a company ‘go digital’ safely?This paper will examine the main roadblocks encountered in digital transformation projects: From lack of holistic vision and clear definition of corporate digital strategy, to talent deficits, failure to plan for scalability, and internal resistance to change. We will share some simple ideas that work for our customers, provide information about ‘ready-to-implement’ technologies, and help construct a basic roadmap for implementing digital transformation projects.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"153 10 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131265298","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-04-01DOI: 10.1109/CITCON.2019.8729114
Syed Suhail Akhtar, T. Abbas, J. Goetz, N. Kandamby
Results from one of the world’s largest cement plants are presented in this paper. The plant incorporates many innovative technologies including being the largest single kiln and a preheater tower with dual-sting ‘hybrid’ low-NOx and CO inline calciner. Commissioned with coal firing, the plant later switched to firing a blend of coal and petcoke in the kiln. The calciner has a seven-second residence time and is capable to burn several types of alternative fuels including bigger and denser fuels such as tire chips and/or solid recovered fuels.Prior to calciner installation, a detailed mathematical modeling exercise using mineral interactive computational fluid dynamics (MI-CFD) was carried out. The simulated results showed higher level of coal burnout in seven seconds’ gas residence time with about 95% meal calcination levels. The CO and NOx emissions were found to be extremely low. The predicted values were later found to be reasonably close to plant data.Plant analysis for the last ten years of operation are presented. The lower NOx emissions enabled the plant to use no or very little SNCR allowing for savings of between 1-2 $M per year, as compared with other plants. Some data and simulated results are presented to highlight calciner performance and, where possible, results are compared with other state of the art calciners. The achieved success from the plant can be replicated to other plants through creating similar combustion and process conditions.
{"title":"A Calciner at its Best","authors":"Syed Suhail Akhtar, T. Abbas, J. Goetz, N. Kandamby","doi":"10.1109/CITCON.2019.8729114","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729114","url":null,"abstract":"Results from one of the world’s largest cement plants are presented in this paper. The plant incorporates many innovative technologies including being the largest single kiln and a preheater tower with dual-sting ‘hybrid’ low-NOx and CO inline calciner. Commissioned with coal firing, the plant later switched to firing a blend of coal and petcoke in the kiln. The calciner has a seven-second residence time and is capable to burn several types of alternative fuels including bigger and denser fuels such as tire chips and/or solid recovered fuels.Prior to calciner installation, a detailed mathematical modeling exercise using mineral interactive computational fluid dynamics (MI-CFD) was carried out. The simulated results showed higher level of coal burnout in seven seconds’ gas residence time with about 95% meal calcination levels. The CO and NOx emissions were found to be extremely low. The predicted values were later found to be reasonably close to plant data.Plant analysis for the last ten years of operation are presented. The lower NOx emissions enabled the plant to use no or very little SNCR allowing for savings of between 1-2 $M per year, as compared with other plants. Some data and simulated results are presented to highlight calciner performance and, where possible, results are compared with other state of the art calciners. The achieved success from the plant can be replicated to other plants through creating similar combustion and process conditions.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"24 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127014266","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-04-01DOI: 10.1109/CITCON.2019.8729117
Stephen Tyrrell, K. Guay
This paper will discuss the replacement of a hydraulically operated triple gate valve with a pneumatically operated double gate valve acting as the inlet feed airlock to the cement coal mill. Implementing this change provides the cement plant production department with the reliability needed for fuel delivery. We will discuss technical details of the project including the issues experienced with the triple gate valve that lead to the replacement project, the specification of a double gate valve replacement, the installation details, commissioning, and a discussion of the reliability increase.
{"title":"Improving Coal Mill Fuel Delivery through Upgrades to the Feed Valve","authors":"Stephen Tyrrell, K. Guay","doi":"10.1109/CITCON.2019.8729117","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729117","url":null,"abstract":"This paper will discuss the replacement of a hydraulically operated triple gate valve with a pneumatically operated double gate valve acting as the inlet feed airlock to the cement coal mill. Implementing this change provides the cement plant production department with the reliability needed for fuel delivery. We will discuss technical details of the project including the issues experienced with the triple gate valve that lead to the replacement project, the specification of a double gate valve replacement, the installation details, commissioning, and a discussion of the reliability increase.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"124 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"117327812","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-04-01DOI: 10.1109/CITCON.2019.8729107
M. Fanslow
IEEE 499 Recommended Practice for Cement Plant Electric Drives and Related Electrical Equipment, was written by a committee of users, manufacturers and engineering consultants for the purpose of providing a common minimum standard on requirements for electric drives in the cement industry. The standard covers electric motors and generators, motor control equipment, control circuits, as well as overcurrent and undervoltage protection. The standard also details cement industry specific applications such as grinding mills, kiln drives and clinker coolers.
{"title":"The Importance of IEEE 499 When Specifying Cement Plant Drive Applications","authors":"M. Fanslow","doi":"10.1109/CITCON.2019.8729107","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729107","url":null,"abstract":"IEEE 499 Recommended Practice for Cement Plant Electric Drives and Related Electrical Equipment, was written by a committee of users, manufacturers and engineering consultants for the purpose of providing a common minimum standard on requirements for electric drives in the cement industry. The standard covers electric motors and generators, motor control equipment, control circuits, as well as overcurrent and undervoltage protection. The standard also details cement industry specific applications such as grinding mills, kiln drives and clinker coolers.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"11 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114938684","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-04-01DOI: 10.1109/CITCON.2019.8729101
Syed Suhail Akhtar, P. Edwards
The traditional process of improving air systems originally depended on getting advice from compressor companies whose primary focus was improving the supply side with the motivation of selling equipment for profit. A different approach was found which focused on the return-on-investment (ROI) portion of projects. This led to an improved process which didn’t focus on smaller, incremental gains available on the supply side. Instead, it looked at demand improvements combined with better control of existing assets. That led to quite a few innovations in the cement industry on both the demand and control side. With as much promise as that had, the success rate of the projects was mixed. Re-audits at several plants showed that many of the gains were not sustained and that the business process of air improvements was missing critical steps. Those steps are called by different names by different companies including "ongoing optimization," "sustained savings," "persistent commissioning," and others. Regardless of the terminology, this process filled gap with the new steps required to optimize air systems and then keep the savings. This paper examines the progression of both business and technical aspects of air system improvements with a heavy emphasis on these new critical steps such information systems, operator education and state of the art point of use practice.
{"title":"The Path to Sustainable, Optimized Compressed Air Systems","authors":"Syed Suhail Akhtar, P. Edwards","doi":"10.1109/CITCON.2019.8729101","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729101","url":null,"abstract":"The traditional process of improving air systems originally depended on getting advice from compressor companies whose primary focus was improving the supply side with the motivation of selling equipment for profit. A different approach was found which focused on the return-on-investment (ROI) portion of projects. This led to an improved process which didn’t focus on smaller, incremental gains available on the supply side. Instead, it looked at demand improvements combined with better control of existing assets. That led to quite a few innovations in the cement industry on both the demand and control side. With as much promise as that had, the success rate of the projects was mixed. Re-audits at several plants showed that many of the gains were not sustained and that the business process of air improvements was missing critical steps. Those steps are called by different names by different companies including \"ongoing optimization,\" \"sustained savings,\" \"persistent commissioning,\" and others. Regardless of the terminology, this process filled gap with the new steps required to optimize air systems and then keep the savings. This paper examines the progression of both business and technical aspects of air system improvements with a heavy emphasis on these new critical steps such information systems, operator education and state of the art point of use practice.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"23 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115374201","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-04-01DOI: 10.1109/CITCON.2019.8729110
P.E. Samy Faried, Wolfgang Hakelberg
According to NFPA 70E, arc flash incidents occur five to ten times each day. The occurrence of an arc flash is the most serious fault within a power system. The destructive impacts of an arc flash event can lead to severe injuries of operating personnel, costly damage of the switchgear, and to long outages of the system. Active arc elimination systems can mitigate the above-named consequences. They extinguish an internal arc by redirecting the uncontrolled energy release into a defined and controlled bolted connection of all 3 phases to earth potential. Arc elimination devices are designed to detect and quench a of protection for personnel and equipment. This paper encompasses the highlights of OSHA’s Final Rule (forecasted to save 20 lives annually) that became a law in July, 2014 and a general overview of different arc flash protection devices available on the market. The Final Rule introduced new language, methods of calculations, and deadlines. Also included are the highlights of the changes in IEEE 1584-2018 which is the Guide for Performing Arc-Flash Hazard Calculations and NFPA 70E 2018 which is Standard for Electrical Safety in the Workplace. A portion of this paper was presented at IEEE PCIC Technical Conference in 2017 at Calgary, Alberta.
{"title":"Arc Flash – IEEE 1584-2018, NFPA 70E 2018, & OSHA Final Rule Highlights and Arc Flash Mitigation Technologies","authors":"P.E. Samy Faried, Wolfgang Hakelberg","doi":"10.1109/CITCON.2019.8729110","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729110","url":null,"abstract":"According to NFPA 70E, arc flash incidents occur five to ten times each day. The occurrence of an arc flash is the most serious fault within a power system. The destructive impacts of an arc flash event can lead to severe injuries of operating personnel, costly damage of the switchgear, and to long outages of the system. Active arc elimination systems can mitigate the above-named consequences. They extinguish an internal arc by redirecting the uncontrolled energy release into a defined and controlled bolted connection of all 3 phases to earth potential. Arc elimination devices are designed to detect and quench a of protection for personnel and equipment. This paper encompasses the highlights of OSHA’s Final Rule (forecasted to save 20 lives annually) that became a law in July, 2014 and a general overview of different arc flash protection devices available on the market. The Final Rule introduced new language, methods of calculations, and deadlines. Also included are the highlights of the changes in IEEE 1584-2018 which is the Guide for Performing Arc-Flash Hazard Calculations and NFPA 70E 2018 which is Standard for Electrical Safety in the Workplace. A portion of this paper was presented at IEEE PCIC Technical Conference in 2017 at Calgary, Alberta.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123200596","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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