Pub Date : 2014-04-13DOI: 10.1109/CITCON.2014.6820113
J. Ross
In today's industry there has been more emphasis placed on increasing the reliability of key equipment to reduce cost and maximize profits. As the cement industry strives to come out of the recent recession and prepare for increased demands in production, equipment reliability will become more important. For many companies, the recession brought about downsizing of plants, personnel and budgets utilized on anything other than essential maintenance of equipment. Consequently, we are faced with equipment that will need more maintenance with less maintenance staff to actually perform the required maintenance. Management is faced with the challenge of finding the resources both in experienced personnel and the maintenance budget to optimize the efficiency of plant equipment. With this in mind, it is increasingly more important to look at ways to keep the equipment in stable operating condition. The purpose of this paper is to define what is necessary to increase the reliability and stability of a cement kiln.
{"title":"Increasing reliability by maintaining kiln stability","authors":"J. Ross","doi":"10.1109/CITCON.2014.6820113","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820113","url":null,"abstract":"In today's industry there has been more emphasis placed on increasing the reliability of key equipment to reduce cost and maximize profits. As the cement industry strives to come out of the recent recession and prepare for increased demands in production, equipment reliability will become more important. For many companies, the recession brought about downsizing of plants, personnel and budgets utilized on anything other than essential maintenance of equipment. Consequently, we are faced with equipment that will need more maintenance with less maintenance staff to actually perform the required maintenance. Management is faced with the challenge of finding the resources both in experienced personnel and the maintenance budget to optimize the efficiency of plant equipment. With this in mind, it is increasingly more important to look at ways to keep the equipment in stable operating condition. The purpose of this paper is to define what is necessary to increase the reliability and stability of a cement kiln.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"39 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131058264","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 : 2014-04-13DOI: 10.1109/CITCON.2014.6820112
S. Drzymala
This paper will address the methodology used to bring two cement companies and related vertically integrated facilities into compliance with NFPA 70E® requirements, utilizing in-house resources. With the help of commonly available software tools, it is feasible to conquer this seemingly impossible task in an economical fashion.
{"title":"Implementation of an arc flash program","authors":"S. Drzymala","doi":"10.1109/CITCON.2014.6820112","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820112","url":null,"abstract":"This paper will address the methodology used to bring two cement companies and related vertically integrated facilities into compliance with NFPA 70E® requirements, utilizing in-house resources. With the help of commonly available software tools, it is feasible to conquer this seemingly impossible task in an economical fashion.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"367 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115894021","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 : 2014-04-13DOI: 10.1109/CITCON.2014.6820108
Andy Holtom, D. Keller, P. Van Winkle
Many considerations must be taken into account when designing and selecting drives for overland conveyors. This paper will concentrate on the key design factors, drive location, client and site influences, equipment vendor, and recommended practices during the design and selection process of the drive equipment. In addition, design program alternatives will be discussed, along with key input item variables which may influence the design process. Design related considerations for multiple VFD's and their position on the conveyor will also be included. Field related tolerances, start-up considerations and operating conditions will also be discussed as to how these factors relate to the original design. Finally, discussion of past project lessons learned.
{"title":"Drives for overland conveyors and lessons learned","authors":"Andy Holtom, D. Keller, P. Van Winkle","doi":"10.1109/CITCON.2014.6820108","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820108","url":null,"abstract":"Many considerations must be taken into account when designing and selecting drives for overland conveyors. This paper will concentrate on the key design factors, drive location, client and site influences, equipment vendor, and recommended practices during the design and selection process of the drive equipment. In addition, design program alternatives will be discussed, along with key input item variables which may influence the design process. Design related considerations for multiple VFD's and their position on the conveyor will also be included. Field related tolerances, start-up considerations and operating conditions will also be discussed as to how these factors relate to the original design. Finally, discussion of past project lessons learned.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"14 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128858024","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 : 2014-04-13DOI: 10.1109/CITCON.2014.6820122
Thomas Schmitz
As the market demands efficient, highly flexible and high capacity plants for cement production, it was time to develop an innovative drive concept to cope with these demands: the world's first vertical roller mill with driven rollers. With this concept, it is the rollers of the vertical roller mill that are driven, not - as is usually the case - the grinding table. With the roller-driven vertical mill the market is offered an innovative drive concept that is specifically suitable for reliably driving large vertical mills. In addition to the obvious advantages in terms of plant availability, this concept offers process-technological advantages and allows a highly efficient comminution process in vertical mills. Due to the variable speed drives, the concept is particularly suited to grinding plants for the production of ultrafine cements and to applications requiring the production of a wide range of the most varied cements. When the first roller-driven vertical mill was put into operation, it robustly demonstrated its mechanical functionality and operational reliability.
{"title":"The world's first vertical roller mill with driven rollers","authors":"Thomas Schmitz","doi":"10.1109/CITCON.2014.6820122","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820122","url":null,"abstract":"As the market demands efficient, highly flexible and high capacity plants for cement production, it was time to develop an innovative drive concept to cope with these demands: the world's first vertical roller mill with driven rollers. With this concept, it is the rollers of the vertical roller mill that are driven, not - as is usually the case - the grinding table. With the roller-driven vertical mill the market is offered an innovative drive concept that is specifically suitable for reliably driving large vertical mills. In addition to the obvious advantages in terms of plant availability, this concept offers process-technological advantages and allows a highly efficient comminution process in vertical mills. Due to the variable speed drives, the concept is particularly suited to grinding plants for the production of ultrafine cements and to applications requiring the production of a wide range of the most varied cements. When the first roller-driven vertical mill was put into operation, it robustly demonstrated its mechanical functionality and operational reliability.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"40 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115298867","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 : 2014-04-13DOI: 10.1109/CITCON.2014.6820102
W. Finley
In modern industrial systems it can be shown that there is a large advantage in total cost of ownership to match driven equipment, adjustable frequency drives (AFD), and motors at ratings that fully utilize these components. Many industries see a demand for increasingly larger power ratings where the sizing of the components and selection of operating points becomes much more critical than their smaller predecessors. These operating points include the speed, voltage, and temperature that the equipment is capable of operating. These factors will impact the initial capital cost of the system, the operating cost in terms of power consumption, and the flexibility and the robustness of the system. The goal of this paper is to demonstrate the importance of selecting the appropriate operating voltage, as well as the benefits of matching fully utilized components. These benefits can be shown to provide enough return on investment to justify collaborative development efforts between various equipment manufacturers as well as electrical and mechanical designers within a common equipment manufacturer, thereby providing the most cost effective and reliable solutions.
{"title":"Advantages of optimizing motor & drives to ensure best performance & total cost of ownership","authors":"W. Finley","doi":"10.1109/CITCON.2014.6820102","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820102","url":null,"abstract":"In modern industrial systems it can be shown that there is a large advantage in total cost of ownership to match driven equipment, adjustable frequency drives (AFD), and motors at ratings that fully utilize these components. Many industries see a demand for increasingly larger power ratings where the sizing of the components and selection of operating points becomes much more critical than their smaller predecessors. These operating points include the speed, voltage, and temperature that the equipment is capable of operating. These factors will impact the initial capital cost of the system, the operating cost in terms of power consumption, and the flexibility and the robustness of the system. The goal of this paper is to demonstrate the importance of selecting the appropriate operating voltage, as well as the benefits of matching fully utilized components. These benefits can be shown to provide enough return on investment to justify collaborative development efforts between various equipment manufacturers as well as electrical and mechanical designers within a common equipment manufacturer, thereby providing the most cost effective and reliable solutions.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"8 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130281725","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 : 2014-04-13DOI: 10.1109/CITCON.2014.6820103
Karl Menzel, K. Rohloff
Alternative Fuels are successfully used in the Cement Industry in order to reduce production costs, to preserve fossil fuel resources and to minimize anthropogenic CO2 emissions. For co-combustion with standard equipment in cement plants the waste derived fuels have to be prepared in mechanical fuel preparation plants. The fuel must be sized to less than 25/80 mm so that it is entrained in the gas stream or flame and totally burns out within the short retention time in the calciner or in the kiln. To increase the fuel input especially of coarse alternative fuels e.g. tires chips with dimension up to 150 mm, an adapted fuel handling and dosing system is necessary. Alternatively to the direct dosing into the calciner, coarser fuels with dimension of up to 300 mm can be treated in a specialized combustion system that is connected to a standard calciner system. The paper gives insight into the introduction of tire chips to a calciner in Morocco and the arrangement of the first installation of the “Step Combustor” system in Germany.
{"title":"Alternative fuels — How to increase the use of coarse alternative fuels in the cement industry","authors":"Karl Menzel, K. Rohloff","doi":"10.1109/CITCON.2014.6820103","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820103","url":null,"abstract":"Alternative Fuels are successfully used in the Cement Industry in order to reduce production costs, to preserve fossil fuel resources and to minimize anthropogenic CO2 emissions. For co-combustion with standard equipment in cement plants the waste derived fuels have to be prepared in mechanical fuel preparation plants. The fuel must be sized to less than 25/80 mm so that it is entrained in the gas stream or flame and totally burns out within the short retention time in the calciner or in the kiln. To increase the fuel input especially of coarse alternative fuels e.g. tires chips with dimension up to 150 mm, an adapted fuel handling and dosing system is necessary. Alternatively to the direct dosing into the calciner, coarser fuels with dimension of up to 300 mm can be treated in a specialized combustion system that is connected to a standard calciner system. The paper gives insight into the introduction of tire chips to a calciner in Morocco and the arrangement of the first installation of the “Step Combustor” system in Germany.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"35 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122019434","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 : 2014-04-13DOI: 10.1109/CITCON.2014.6820115
Melissa R. Dale, David Carichner
A significant energy savings can be achieved by converting inefficient direct-driven rotary vane compressor applications to belt-driven applications.
通过将低效的直接驱动旋转叶片压缩机应用转换为皮带驱动应用，可以实现显著的节能。
{"title":"Motor conversion for reduced energy consumption in compressor applications","authors":"Melissa R. Dale, David Carichner","doi":"10.1109/CITCON.2014.6820115","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820115","url":null,"abstract":"A significant energy savings can be achieved by converting inefficient direct-driven rotary vane compressor applications to belt-driven applications.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"6 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124975856","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 : 2014-04-13DOI: 10.1109/CITCON.2014.6820121
Caroline Woywadt
Currently in the cement industry, the trend is toward ever increasing grinding capacities of individual grinding plants. As a result, plant availability and optimized maintenance concepts are becoming more and more important. A modular mill concept allows the continuation of mill operation even if one roller is not available and provides plant availability. The newly developed modular roller mill for grinding cement raw material, cement clinker, and additives with an installed power of up to 12,000 kW was specifically designed to meet those needs. Large cement plants can now be designed with the one-mill concept for both raw material and cement grinding. Investors plan to install small plants and therefore need to keep their initial investment costs at a minimum. This can be achieved by purchasing just one mill. For this intended use the swing mill with its capability to grind different types of raw materials and clinker, interchangeably, depending on market needs is the appropriate solution.
{"title":"The latest innovative technology for vertical roller mills: Modular mill with modular drive system and swing mill solutions","authors":"Caroline Woywadt","doi":"10.1109/CITCON.2014.6820121","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820121","url":null,"abstract":"Currently in the cement industry, the trend is toward ever increasing grinding capacities of individual grinding plants. As a result, plant availability and optimized maintenance concepts are becoming more and more important. A modular mill concept allows the continuation of mill operation even if one roller is not available and provides plant availability. The newly developed modular roller mill for grinding cement raw material, cement clinker, and additives with an installed power of up to 12,000 kW was specifically designed to meet those needs. Large cement plants can now be designed with the one-mill concept for both raw material and cement grinding. Investors plan to install small plants and therefore need to keep their initial investment costs at a minimum. This can be achieved by purchasing just one mill. For this intended use the swing mill with its capability to grind different types of raw materials and clinker, interchangeably, depending on market needs is the appropriate solution.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"18 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131479417","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 : 2014-04-13DOI: 10.1109/CITCON.2014.6820125
P. Sopher
This document will explore using the highly efficient 3-D design technology for developing Engineering drawings for various capital design projects for cement plants and demonstrate how using 3-D modeling can be used to make plant projects more efficient. Design examples of different project types utilizing 3-D CAD will be examined. One of the projects that will be featured is a new Gas Conditioning Tower on an existing four-stage preheater tower. This paper will delve into the positives and negatives in using a 3-D modeling program for these types of projects. Various 3-D screen shots of different types of projects will be included along with an overall project development summary for each.
{"title":"Using 3-D modeling for plant capital projects","authors":"P. Sopher","doi":"10.1109/CITCON.2014.6820125","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820125","url":null,"abstract":"This document will explore using the highly efficient 3-D design technology for developing Engineering drawings for various capital design projects for cement plants and demonstrate how using 3-D modeling can be used to make plant projects more efficient. Design examples of different project types utilizing 3-D CAD will be examined. One of the projects that will be featured is a new Gas Conditioning Tower on an existing four-stage preheater tower. This paper will delve into the positives and negatives in using a 3-D modeling program for these types of projects. Various 3-D screen shots of different types of projects will be included along with an overall project development summary for each.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"89 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114489183","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 : 2014-04-13DOI: 10.1109/CITCON.2014.6820105
J. Kline, Charles Kline
Concrete is the second most widely used commodity globally, with estimated production at over 15 billion tons per year. It is estimated that 3.6 billion tons of cement were produced in 2012 accounting for approximately 5% of the global anthropogenic CO2 emissions. The Cement Sustainability Initiative (CSI), along with the International Energy Agency (EIA) have developed a road map for CO2 reductions in the cement industry. The IEA/CSI “blue map” calls for a reduction of approximately 50% in the specific CO2 emissions per ton of cement by the year 2050. The blue map emphasizes continued progress in the three traditional levers for CO2 reduction, but also indicates that these three levers will only achieve half of the targeted reduction. Many cement companies are exploring additional ways to achieve CO2 reductions. This paper reviews the progress to date and some of the many projects underway in the cement industry.
{"title":"Cement and CO2: what's happening","authors":"J. Kline, Charles Kline","doi":"10.1109/CITCON.2014.6820105","DOIUrl":"https://doi.org/10.1109/CITCON.2014.6820105","url":null,"abstract":"Concrete is the second most widely used commodity globally, with estimated production at over 15 billion tons per year. It is estimated that 3.6 billion tons of cement were produced in 2012 accounting for approximately 5% of the global anthropogenic CO2 emissions. The Cement Sustainability Initiative (CSI), along with the International Energy Agency (EIA) have developed a road map for CO2 reductions in the cement industry. The IEA/CSI “blue map” calls for a reduction of approximately 50% in the specific CO2 emissions per ton of cement by the year 2050. The blue map emphasizes continued progress in the three traditional levers for CO2 reduction, but also indicates that these three levers will only achieve half of the targeted reduction. Many cement companies are exploring additional ways to achieve CO2 reductions. This paper reviews the progress to date and some of the many projects underway in the cement industry.","PeriodicalId":422446,"journal":{"name":"2014 IEEE-IAS/PCA Cement Industry Technical Conference","volume":"67 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133089079","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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