Pub Date : 2010-05-20DOI: 10.1109/CITCON.2010.5469767
E. Dutrow, E. Worrell
In the mid-1990's, the U.S. Environmental Protection Agency (EPA) approached U.S. cement producers to work together to improve the energy efficiency of U.S. cement plants. Initially, EPA and the producers developed basic tools for identifying potential energy reductions and for estimating cement plant greenhouse gas emissions. Then, through EPA's ENERGY STAR® Partnership, the need for corporate energy management was emphasized along with careful measurement and tracking of energy and benchmarking of plant energy performance among the industry nationwide. This paper describes the engagement strategy EPA employed, the tools that were produced to aid cement producers to improve, and the results accomplished through this partnership.
{"title":"Shifting energy performance in U.S. cement production","authors":"E. Dutrow, E. Worrell","doi":"10.1109/CITCON.2010.5469767","DOIUrl":"https://doi.org/10.1109/CITCON.2010.5469767","url":null,"abstract":"In the mid-1990's, the U.S. Environmental Protection Agency (EPA) approached U.S. cement producers to work together to improve the energy efficiency of U.S. cement plants. Initially, EPA and the producers developed basic tools for identifying potential energy reductions and for estimating cement plant greenhouse gas emissions. Then, through EPA's ENERGY STAR® Partnership, the need for corporate energy management was emphasized along with careful measurement and tracking of energy and benchmarking of plant energy performance among the industry nationwide. This paper describes the engagement strategy EPA employed, the tools that were produced to aid cement producers to improve, and the results accomplished through this partnership.","PeriodicalId":250209,"journal":{"name":"2010 IEEE-IAS/PCA 52nd Cement Industry Technical Conference","volume":"49 3 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2010-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115242318","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 : 2010-05-20DOI: 10.1109/CITCON.2010.5469763
M. Porter
Computational Fluid Dynamics (CFD) tools provide a means for predicting -in great detail -the flow patterns that can be expected within process equipment at concrete plants. This information enables significant plant improvements through the implementation of oftentimes minimal modifications. CFD tools can also be used during the plant's design phase to ensure proper operation after commissioning. The paper will discuss several areas of plant design where CFD tools have been implemented to provide operational benefit. Topics to be discussed include: (a) reducing pressure drop through process components, (b) improving the distribution of particle-laden flows into hoppers, resulting in less bag wear, (c) reducing/eliminating tube sheet scouring in clinker coolers, (d) improving utilization of existing equipment, (e) the use of Lagrangian modeling techniques to predict dust loading paths and to size and place reaction injectors, and (f) implementing reaction chemistry to model combustion dynamics. While the primary focus of the paper is baghouse operation, discussion will also be provided concerning kiln dynamics, clinker coolers and injectors for NOx and mercury reduction in flue gas.
{"title":"Profiting from better air flow in baghouses","authors":"M. Porter","doi":"10.1109/CITCON.2010.5469763","DOIUrl":"https://doi.org/10.1109/CITCON.2010.5469763","url":null,"abstract":"Computational Fluid Dynamics (CFD) tools provide a means for predicting -in great detail -the flow patterns that can be expected within process equipment at concrete plants. This information enables significant plant improvements through the implementation of oftentimes minimal modifications. CFD tools can also be used during the plant's design phase to ensure proper operation after commissioning. The paper will discuss several areas of plant design where CFD tools have been implemented to provide operational benefit. Topics to be discussed include: (a) reducing pressure drop through process components, (b) improving the distribution of particle-laden flows into hoppers, resulting in less bag wear, (c) reducing/eliminating tube sheet scouring in clinker coolers, (d) improving utilization of existing equipment, (e) the use of Lagrangian modeling techniques to predict dust loading paths and to size and place reaction injectors, and (f) implementing reaction chemistry to model combustion dynamics. While the primary focus of the paper is baghouse operation, discussion will also be provided concerning kiln dynamics, clinker coolers and injectors for NOx and mercury reduction in flue gas.","PeriodicalId":250209,"journal":{"name":"2010 IEEE-IAS/PCA 52nd Cement Industry Technical Conference","volume":"29 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2010-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128222768","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 : 2010-05-20DOI: 10.1109/CITCON.2010.5469774
Desi A. Delgado
Large gear reducers for vertical roller mills have a lead time of over 2 years. The same can be expected of their spare parts. A catastrophic failure of a gear reducer can be detrimental to a company's production and financial security. This paper discusses the measures taken to bring a vertical roller mill, whose gear reducer was subject to a catastrophic failure, back to 100% production in less than 6 months.
{"title":"Onsite repair of a large gear reducer for a vertical roller mill","authors":"Desi A. Delgado","doi":"10.1109/CITCON.2010.5469774","DOIUrl":"https://doi.org/10.1109/CITCON.2010.5469774","url":null,"abstract":"Large gear reducers for vertical roller mills have a lead time of over 2 years. The same can be expected of their spare parts. A catastrophic failure of a gear reducer can be detrimental to a company's production and financial security. This paper discusses the measures taken to bring a vertical roller mill, whose gear reducer was subject to a catastrophic failure, back to 100% production in less than 6 months.","PeriodicalId":250209,"journal":{"name":"2010 IEEE-IAS/PCA 52nd Cement Industry Technical Conference","volume":"68 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2010-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123350924","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 : 2010-05-20DOI: 10.1109/CITCON.2010.5470072
D. Crowley
With the United States Environmental Protection Agency (EPA) drafting guidelines to control mercury emissions many in the Cement Industry are looking at opportunities to manage these emissions in a cost effective way. This paper summarizes three years of mercury management practice at Titan America's kiln line in Florida. Topics include the operational practices that support a materials balance management protocol and the testing done to better identify the mercury cycle specific to the main dust collector. Finally a successful theoretical application of mercury management through dust disposal is summarized with estimates of the cost of application of such a system.
{"title":"Cement kiln mercury reduction strategies a case study in materials management","authors":"D. Crowley","doi":"10.1109/CITCON.2010.5470072","DOIUrl":"https://doi.org/10.1109/CITCON.2010.5470072","url":null,"abstract":"With the United States Environmental Protection Agency (EPA) drafting guidelines to control mercury emissions many in the Cement Industry are looking at opportunities to manage these emissions in a cost effective way. This paper summarizes three years of mercury management practice at Titan America's kiln line in Florida. Topics include the operational practices that support a materials balance management protocol and the testing done to better identify the mercury cycle specific to the main dust collector. Finally a successful theoretical application of mercury management through dust disposal is summarized with estimates of the cost of application of such a system.","PeriodicalId":250209,"journal":{"name":"2010 IEEE-IAS/PCA 52nd Cement Industry Technical Conference","volume":"188 5 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2010-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132448898","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 : 2010-05-20DOI: 10.1109/CITCON.2010.5470074
D. Longhurst
There are literally thousands of ball mills in use throughout the world, many of them in the cement industry. Few installations have a comprehensible method of controlling and recording exactly what ball size distribution is in, or should be in, the ball mill. As mills are supplied for ever increasing capacities, the ball size distribution and wear exact a tremendous effect on the profitability of producing finish cement. Improper size distribution or filling level of the ball charge can easily reduce the efficiency of grinding (possible production rate) by 5% to 20%. Relating an efficiency loss of only 5% for a mill with a capacity of 150 Stph, results in a loss of saleable cement at $90/Ston of $5.0 million per year. Online, real time information from the grinding process has aided in the attempt to reach peak performance, but for many grinding installations, maintenance of the grinding media remains in the dark ages.
{"title":"Economics and methodology of ball mill media maintenance","authors":"D. Longhurst","doi":"10.1109/CITCON.2010.5470074","DOIUrl":"https://doi.org/10.1109/CITCON.2010.5470074","url":null,"abstract":"There are literally thousands of ball mills in use throughout the world, many of them in the cement industry. Few installations have a comprehensible method of controlling and recording exactly what ball size distribution is in, or should be in, the ball mill. As mills are supplied for ever increasing capacities, the ball size distribution and wear exact a tremendous effect on the profitability of producing finish cement. Improper size distribution or filling level of the ball charge can easily reduce the efficiency of grinding (possible production rate) by 5% to 20%. Relating an efficiency loss of only 5% for a mill with a capacity of 150 Stph, results in a loss of saleable cement at $90/Ston of $5.0 million per year. Online, real time information from the grinding process has aided in the attempt to reach peak performance, but for many grinding installations, maintenance of the grinding media remains in the dark ages.","PeriodicalId":250209,"journal":{"name":"2010 IEEE-IAS/PCA 52nd Cement Industry Technical Conference","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2010-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129374362","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 : 2010-05-20DOI: 10.1109/CITCON.2010.5469765
D. Laudal, J. Kay, Michal L. Jones, J. Pavlish
Mercury is a known neurological toxin that the U.S. Environmental Protection Agency (EPA) regulates under the National Emission Standards for Hazardous Air Pollutants (NESHAP) for municipal waste incinerators and medical waste incinerators. Although later vacated by the courts, mercury regulations were also promulgated for coal-fired utilities. Under the existing and proposed NESHAP for the portland cement industry, EPA is proposing to regulate mercury for the portland cement industry for both new and existing cement plants. A substantial body of information has been generated in the coal-fired boiler industry for activated carbon injection control systems. Utilizing this knowledge base and the limited data from the cement industry, issues and opportunities for activated carbon injection to control mercury from cement kilns will be discussed.
{"title":"Issues associated with the use of activated carbon for mercury control in cement kilns","authors":"D. Laudal, J. Kay, Michal L. Jones, J. Pavlish","doi":"10.1109/CITCON.2010.5469765","DOIUrl":"https://doi.org/10.1109/CITCON.2010.5469765","url":null,"abstract":"Mercury is a known neurological toxin that the U.S. Environmental Protection Agency (EPA) regulates under the National Emission Standards for Hazardous Air Pollutants (NESHAP) for municipal waste incinerators and medical waste incinerators. Although later vacated by the courts, mercury regulations were also promulgated for coal-fired utilities. Under the existing and proposed NESHAP for the portland cement industry, EPA is proposing to regulate mercury for the portland cement industry for both new and existing cement plants. A substantial body of information has been generated in the coal-fired boiler industry for activated carbon injection control systems. Utilizing this knowledge base and the limited data from the cement industry, issues and opportunities for activated carbon injection to control mercury from cement kilns will be discussed.","PeriodicalId":250209,"journal":{"name":"2010 IEEE-IAS/PCA 52nd Cement Industry Technical Conference","volume":"86 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2010-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127134185","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 : 2010-05-20DOI: 10.1109/CITCON.2010.5469766
W. Gebhart
There is more than alignment involved to get the best performance from the kiln's support rollers.
有更多的对准涉及到从窑的支撑辊获得最佳性能。
{"title":"Optimization of kiln alignment","authors":"W. Gebhart","doi":"10.1109/CITCON.2010.5469766","DOIUrl":"https://doi.org/10.1109/CITCON.2010.5469766","url":null,"abstract":"There is more than alignment involved to get the best performance from the kiln's support rollers.","PeriodicalId":250209,"journal":{"name":"2010 IEEE-IAS/PCA 52nd Cement Industry Technical Conference","volume":"80 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2010-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125233602","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 : 2010-05-20DOI: 10.1109/CITCON.2010.5469771
Marvin Schmitt, D. M. Lorimer
Control system coordination in today's manufacturing facilities is crucial to achieve performance objectives. Cement facilities daily consumption can exceed 15,000 tones limestone rock, 1,100 tones of coal, and 1 Gig watt-hour electrical demand. With huge facilities the equipment availability becomes a key indicator to overall facility performance. Control systems need to help production and maintenance teams achieve the availability goals. This cascades to higher control system availability and functionality requirements. Designers are utilizing innovative software methods to integrate systems to allow for flexible and reliable service while ensuring proper equipment alarming and interlock protection. Software objects are able to encapsulate the desired functionality which provides for better system standardization and overall coordination. We all want to build successful control systems. The following discussion will highlight several key aspects to PCS installations that the design teams need to understand and consider throughout the design of a highly available PCS. The topics are based on our personal experiences while supporting large facility integration projects.
{"title":"Equipment availability in control systems","authors":"Marvin Schmitt, D. M. Lorimer","doi":"10.1109/CITCON.2010.5469771","DOIUrl":"https://doi.org/10.1109/CITCON.2010.5469771","url":null,"abstract":"Control system coordination in today's manufacturing facilities is crucial to achieve performance objectives. Cement facilities daily consumption can exceed 15,000 tones limestone rock, 1,100 tones of coal, and 1 Gig watt-hour electrical demand. With huge facilities the equipment availability becomes a key indicator to overall facility performance. Control systems need to help production and maintenance teams achieve the availability goals. This cascades to higher control system availability and functionality requirements. Designers are utilizing innovative software methods to integrate systems to allow for flexible and reliable service while ensuring proper equipment alarming and interlock protection. Software objects are able to encapsulate the desired functionality which provides for better system standardization and overall coordination. We all want to build successful control systems. The following discussion will highlight several key aspects to PCS installations that the design teams need to understand and consider throughout the design of a highly available PCS. The topics are based on our personal experiences while supporting large facility integration projects.","PeriodicalId":250209,"journal":{"name":"2010 IEEE-IAS/PCA 52nd Cement Industry Technical Conference","volume":"8 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2010-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121278525","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 : 2010-05-20DOI: 10.1109/CITCON.2010.5470068
G. Seggewiss, M. Fanslow
High mechanical stresses can lead to premature failure of rotating equipment. Understanding the mechanism causing vibrations helps in proper prediction and monitoring activities to minimize harmful effects of vibrations. This primer provides a mechanical background and measures to mitigate mechanical stresses in rotating equipment involving electric motors and drives. Vibration problems can occur at any time in the life of rotating equipment but is best reviewed and mitigated at the start of the equipment life with analysis and measurement to ensure long trouble free operation. This paper is intended to provide an overview of vibration issues with larger motors and drives in the cement industry.
{"title":"Electro-mechanical considerations for long term drive life in fan, mill, and conveyor applications","authors":"G. Seggewiss, M. Fanslow","doi":"10.1109/CITCON.2010.5470068","DOIUrl":"https://doi.org/10.1109/CITCON.2010.5470068","url":null,"abstract":"High mechanical stresses can lead to premature failure of rotating equipment. Understanding the mechanism causing vibrations helps in proper prediction and monitoring activities to minimize harmful effects of vibrations. This primer provides a mechanical background and measures to mitigate mechanical stresses in rotating equipment involving electric motors and drives. Vibration problems can occur at any time in the life of rotating equipment but is best reviewed and mitigated at the start of the equipment life with analysis and measurement to ensure long trouble free operation. This paper is intended to provide an overview of vibration issues with larger motors and drives in the cement industry.","PeriodicalId":250209,"journal":{"name":"2010 IEEE-IAS/PCA 52nd Cement Industry Technical Conference","volume":"73 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2010-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127665974","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 : 2010-05-20DOI: 10.1109/CITCON.2010.5469773
G. R. Gerber, A. B. Amin
This paper describes the retrofit of a Cement Kiln Drive with a Direct Hydraulic Drive (DHD) replacing an existing DC drive with gearbox. DHD uses Low Speed High Torque Hydraulic motor without any intermediate gearing.
{"title":"Successful retrofit upgrade of a Kiln Drive application at Lehigh Cement, York, Pa by replacing existing electromechanical (D.C.) Drive with Direct Hydraulic Drive system","authors":"G. R. Gerber, A. B. Amin","doi":"10.1109/CITCON.2010.5469773","DOIUrl":"https://doi.org/10.1109/CITCON.2010.5469773","url":null,"abstract":"This paper describes the retrofit of a Cement Kiln Drive with a Direct Hydraulic Drive (DHD) replacing an existing DC drive with gearbox. DHD uses Low Speed High Torque Hydraulic motor without any intermediate gearing.","PeriodicalId":250209,"journal":{"name":"2010 IEEE-IAS/PCA 52nd Cement Industry Technical Conference","volume":"36 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2010-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115111757","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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