Pub Date : 1996-04-14DOI: 10.1109/CITCON.1996.506024
R. J. Schmidt, M. Huber
Coal pulverizers have utilized a static classifier to generate the desired product fineness which could be effectively burned in a kiln, furnace or boiler. Now there is interest in obtaining a finer product that can enhance the burning efficiency in a coal fired kiln. This is important in light of the increased use of petroleum coke rather than conventional coal. Previously, a secondary fuel would be required to act as a sustainer for the coke due to it's lower volatile content. The turbine style dynamic classifier appears to meet the needs for a new generation classifier to produce the higher product fineness of the ground material.
{"title":"Turbine classifiers for coal pulverizers","authors":"R. J. Schmidt, M. Huber","doi":"10.1109/CITCON.1996.506024","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506024","url":null,"abstract":"Coal pulverizers have utilized a static classifier to generate the desired product fineness which could be effectively burned in a kiln, furnace or boiler. Now there is interest in obtaining a finer product that can enhance the burning efficiency in a coal fired kiln. This is important in light of the increased use of petroleum coke rather than conventional coal. Previously, a secondary fuel would be required to act as a sustainer for the coke due to it's lower volatile content. The turbine style dynamic classifier appears to meet the needs for a new generation classifier to produce the higher product fineness of the ground material.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"56 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"120960390","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 : 1996-04-14DOI: 10.1109/CITCON.1996.507138
H.M. Hecht, G.R. Derick
A low cost control strategy has been developed, which can maintain a mill production near optimum, with little operator intervention. The mill load control strategy is based on the use of classic sensors such as mill sound and recirculating bucket elevator power plus the not-so-often used mill motor power. The heart of the strategy consists of a standard PID algorithm for control: therefore, it is not rule-based or considered an expert system. Because of this, there is no requirement for special hardware or additional computers. The control strategy is integrated into the plant's existing control system which provides training and maintenance benefits. The strategy uses the traditional signals such as mill sound and recirculating bucket elevator power as well as the mill power to determine the mill load level. The load level is defined as the total of the grinding charge and material in the mill. The control strategy attempts to keep this load level as constant as possible. The setpoint for the master controller is derived from the mill motor power. The strategy automatically takes into account changes in material grindability, grinding charge, material retention time and different product types. Maintaining a mill load level is accomplished by balancing the mill load level against the power-derived setpoint.
{"title":"A low cost automatic mill load level control strategy","authors":"H.M. Hecht, G.R. Derick","doi":"10.1109/CITCON.1996.507138","DOIUrl":"https://doi.org/10.1109/CITCON.1996.507138","url":null,"abstract":"A low cost control strategy has been developed, which can maintain a mill production near optimum, with little operator intervention. The mill load control strategy is based on the use of classic sensors such as mill sound and recirculating bucket elevator power plus the not-so-often used mill motor power. The heart of the strategy consists of a standard PID algorithm for control: therefore, it is not rule-based or considered an expert system. Because of this, there is no requirement for special hardware or additional computers. The control strategy is integrated into the plant's existing control system which provides training and maintenance benefits. The strategy uses the traditional signals such as mill sound and recirculating bucket elevator power as well as the mill power to determine the mill load level. The load level is defined as the total of the grinding charge and material in the mill. The control strategy attempts to keep this load level as constant as possible. The setpoint for the master controller is derived from the mill motor power. The strategy automatically takes into account changes in material grindability, grinding charge, material retention time and different product types. Maintaining a mill load level is accomplished by balancing the mill load level against the power-derived setpoint.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126127141","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 : 1996-04-14DOI: 10.1109/CITCON.1996.506016
C. Ouellette
What does a fully integrated consultant offer to the owner of a cement plant that he cannot get from a major electrical turn-key supplier or the owner's own engineering group? In the case of an electrical turn-key supplier, it is an unbiased selection of components making up the lowest cost solution and cement plant process know-how. In the case of the owner's engineering group, it is the application of proven designs gained from repeated experience. For many, the application of a new control system or large drive to an existing plant is a once-in-a-lifetime experience, whereas for the consultant it is a constant evolving process. Good coordination with the consultant's mechanical, civil, and process departments is absolutely necessary to meet today's fast-track construction targets.
{"title":"A consultant's role in design of power and control systems for cement plants","authors":"C. Ouellette","doi":"10.1109/CITCON.1996.506016","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506016","url":null,"abstract":"What does a fully integrated consultant offer to the owner of a cement plant that he cannot get from a major electrical turn-key supplier or the owner's own engineering group? In the case of an electrical turn-key supplier, it is an unbiased selection of components making up the lowest cost solution and cement plant process know-how. In the case of the owner's engineering group, it is the application of proven designs gained from repeated experience. For many, the application of a new control system or large drive to an existing plant is a once-in-a-lifetime experience, whereas for the consultant it is a constant evolving process. Good coordination with the consultant's mechanical, civil, and process departments is absolutely necessary to meet today's fast-track construction targets.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129283164","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 : 1996-04-14DOI: 10.1109/CITCON.1996.506018
N. Nichols
The Color Book series are IEEE Recommended Practice Standards which have been specifically developed for engineers involved with industrial and commercial power systems. This paper explains the meaning of "Consensus Standard" and the process by which they are created and updated. It provides the background as to what entities within IEEE have responsibility for the Color Books, and the background of the authors. A summary of the purpose, contents and application of each Color Book is provided.
{"title":"Creation and use of the IEEE Color Books","authors":"N. Nichols","doi":"10.1109/CITCON.1996.506018","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506018","url":null,"abstract":"The Color Book series are IEEE Recommended Practice Standards which have been specifically developed for engineers involved with industrial and commercial power systems. This paper explains the meaning of \"Consensus Standard\" and the process by which they are created and updated. It provides the background as to what entities within IEEE have responsibility for the Color Books, and the background of the authors. A summary of the purpose, contents and application of each Color Book is provided.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"220 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122613711","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 : 1996-04-14DOI: 10.1109/CITCON.1996.506026
G. Conroy
Two-stage grinding is a natural technological development to maximize the use of roller press technology while guaranteeing a product quality consistent with that of conventional ball mills. In addition, two-stage grinding offers the optimum method to increase the capacity of existing ball mills. Capacity increases between 100 and 200% can be realized as is demonstrated in this paper. Specific power consumption for the overall milling system is also significantly reduced. This paper outlines the industrial experience and results of several two-stage grinding systems to allow for a conclusive report on this type of grinding technology.
{"title":"Industrial application and results of two-stage grinding","authors":"G. Conroy","doi":"10.1109/CITCON.1996.506026","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506026","url":null,"abstract":"Two-stage grinding is a natural technological development to maximize the use of roller press technology while guaranteeing a product quality consistent with that of conventional ball mills. In addition, two-stage grinding offers the optimum method to increase the capacity of existing ball mills. Capacity increases between 100 and 200% can be realized as is demonstrated in this paper. Specific power consumption for the overall milling system is also significantly reduced. This paper outlines the industrial experience and results of several two-stage grinding systems to allow for a conclusive report on this type of grinding technology.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128681939","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 : 1996-04-14DOI: 10.1109/CITCON.1996.506017
W. Lucas, R. Hawks
A majority of the operating cement plants today have medium voltage electrical switching equipment in use which was built in the 1960s and 1970s. Because of plant expansions or to increase reliability and reduce maintenance cost, it may be time to review the remaining life and application of the existing equipment. In order to simplify the decision making process, this paper establishes the basic analysis of evaluating an electrical distribution system and consideration of using vacuum retrofit in existing medium voltage switchgear. The continued demand for vacuum interrupters relates to their successful field experiences, increased confidence in reliability, cost effectiveness and simplicity of the installation.
{"title":"Evaluating your electrical distribution system and modernizing with vacuum technology","authors":"W. Lucas, R. Hawks","doi":"10.1109/CITCON.1996.506017","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506017","url":null,"abstract":"A majority of the operating cement plants today have medium voltage electrical switching equipment in use which was built in the 1960s and 1970s. Because of plant expansions or to increase reliability and reduce maintenance cost, it may be time to review the remaining life and application of the existing equipment. In order to simplify the decision making process, this paper establishes the basic analysis of evaluating an electrical distribution system and consideration of using vacuum retrofit in existing medium voltage switchgear. The continued demand for vacuum interrupters relates to their successful field experiences, increased confidence in reliability, cost effectiveness and simplicity of the installation.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"27 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115026773","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 : 1996-04-14DOI: 10.1109/CITCON.1996.506025
J. Sweeney
The use of a single roller mill to supply kiln feed has always been the most economical approach to new plant construction. However, the ability to design and build mills large enough to supply todays 7500 + tpd cement kilns has sometimes been questioned. The successful start up and operation of the 5.9 meter roller mill at P.T. Semen Gresik's Tuban plant has proven that reliable mills can be built for this application. Years of experience, together with modern computer aided design techniques (FEM), has been the key to opening up the future for large roller mills. The design capabilities needed to successfully produce large mills as well as the operational features of modern roller mills are discussed.
{"title":"Single large roller mill feeds today's jumbo cement plants","authors":"J. Sweeney","doi":"10.1109/CITCON.1996.506025","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506025","url":null,"abstract":"The use of a single roller mill to supply kiln feed has always been the most economical approach to new plant construction. However, the ability to design and build mills large enough to supply todays 7500 + tpd cement kilns has sometimes been questioned. The successful start up and operation of the 5.9 meter roller mill at P.T. Semen Gresik's Tuban plant has proven that reliable mills can be built for this application. Years of experience, together with modern computer aided design techniques (FEM), has been the key to opening up the future for large roller mills. The design capabilities needed to successfully produce large mills as well as the operational features of modern roller mills are discussed.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"25 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124295405","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 : 1996-04-14DOI: 10.1109/CITCON.1996.506012
J. Foster
Historically, DC motor drives have been the most economic solution for cement kiln applications. AC drive technology continues to become more cost competitive, resulting in a trend towards AC kiln drives. Here, the author describes how several factors related to the mechanical characteristics of the kiln and the electrical characteristics of the drive will determine the present optimal drive package for a given kiln application.
{"title":"Kiln drives: past, present and future","authors":"J. Foster","doi":"10.1109/CITCON.1996.506012","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506012","url":null,"abstract":"Historically, DC motor drives have been the most economic solution for cement kiln applications. AC drive technology continues to become more cost competitive, resulting in a trend towards AC kiln drives. Here, the author describes how several factors related to the mechanical characteristics of the kiln and the electrical characteristics of the drive will determine the present optimal drive package for a given kiln application.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"22 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131400932","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 : 1996-04-14DOI: 10.1109/CITCON.1996.506021
D. Gagnon
Portland cement is fabricated with a blend of clinker, gypsum and minor proportions of chemical additives. Clinker being the principal element of this blend, its physical properties have direct effects on Portland cement quality. The temperature of clinker when exiting the process line is one of the most important factors. Grinding of the final blend of clinker-gypsum-additives has temperature limitations for the production of quality cement and more and more cement producers are asked by the end users to offer a cooled Portland cement. These reasons explain why clinker cooling is an important phase in clinker production. The clinker cooler is exposed to extremely difficult operating conditions with a highly abrasive and hot material. When leaving the rotary kiln, clinker is in an unstable state still being partly molten. Grate coolers aeration in the first sections cause a partial fluidisation of clinker. Under certain abnormal conditions, this unstable phase presents upset conditions in the cooler and gives headaches to the operators. Conventional grate coolers could not solve these flow problems on all occasions but new developments in grate coolers have greatly reduced and nearly eliminated these problems. This reports on a successful modification to process lines with a new revolutionary cooling technology.
{"title":"Upgrading a clinker cooler: IKN clinker inlet distribution system (\"KIDS\")","authors":"D. Gagnon","doi":"10.1109/CITCON.1996.506021","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506021","url":null,"abstract":"Portland cement is fabricated with a blend of clinker, gypsum and minor proportions of chemical additives. Clinker being the principal element of this blend, its physical properties have direct effects on Portland cement quality. The temperature of clinker when exiting the process line is one of the most important factors. Grinding of the final blend of clinker-gypsum-additives has temperature limitations for the production of quality cement and more and more cement producers are asked by the end users to offer a cooled Portland cement. These reasons explain why clinker cooling is an important phase in clinker production. The clinker cooler is exposed to extremely difficult operating conditions with a highly abrasive and hot material. When leaving the rotary kiln, clinker is in an unstable state still being partly molten. Grate coolers aeration in the first sections cause a partial fluidisation of clinker. Under certain abnormal conditions, this unstable phase presents upset conditions in the cooler and gives headaches to the operators. Conventional grate coolers could not solve these flow problems on all occasions but new developments in grate coolers have greatly reduced and nearly eliminated these problems. This reports on a successful modification to process lines with a new revolutionary cooling technology.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"27 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116905914","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 : 1996-04-14DOI: 10.1109/CITCON.1996.506013
R. Elsmam, R.A. Errath
It is difficult to make basic equipment decisions, particularly if you have no experience in a certain technology. The rapid changes and improvements, especially in the electronics industry, do not make it any easier and the bottom-line is usually the cost/payback relation. The recent replacement of a hydraulic cement kiln motor drive is presented in the paper. The reasons leading to the need to change to an electrical drive are detailed and operating statistics underline the inefficiency of hydraulic drives. Key messages and recommendations are listed from the case study as a basis for other producers facing the same or similar situation. Although only the experience of one plant, using one supplier, is discussed, it will assist the reader on deciding between a hydraulic or DC drive.
{"title":"Replacing hydraulic kiln drives-key messages and recommendations to cement plant operators from a case study","authors":"R. Elsmam, R.A. Errath","doi":"10.1109/CITCON.1996.506013","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506013","url":null,"abstract":"It is difficult to make basic equipment decisions, particularly if you have no experience in a certain technology. The rapid changes and improvements, especially in the electronics industry, do not make it any easier and the bottom-line is usually the cost/payback relation. The recent replacement of a hydraulic cement kiln motor drive is presented in the paper. The reasons leading to the need to change to an electrical drive are detailed and operating statistics underline the inefficiency of hydraulic drives. Key messages and recommendations are listed from the case study as a basis for other producers facing the same or similar situation. Although only the experience of one plant, using one supplier, is discussed, it will assist the reader on deciding between a hydraulic or DC drive.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"56 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122243104","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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