Pub Date : 1997-04-20DOI: 10.1109/CITCON.1997.599409
M.N. Savit, A. Abrams
Lately, the regulation of airborne contaminants has become a major focus of both the Occupational Health and Safety Act (OSHA) and Mine Safety Health Act (MSHA) in the USA. Given this focus, the mining industry in general, and the cement industry in particular, must be particularly sensitive to regulatory trends regarding airborne or dustborne pathogens or irritants. Recent developments reveal that several disturbing trends are building in the regulatory environment. Two of them are explored in this paper.
{"title":"Risks that you can live with regulations that you can live without regulation of crystalline silica and hexavalent chromium in the cement industry","authors":"M.N. Savit, A. Abrams","doi":"10.1109/CITCON.1997.599409","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599409","url":null,"abstract":"Lately, the regulation of airborne contaminants has become a major focus of both the Occupational Health and Safety Act (OSHA) and Mine Safety Health Act (MSHA) in the USA. Given this focus, the mining industry in general, and the cement industry in particular, must be particularly sensitive to regulatory trends regarding airborne or dustborne pathogens or irritants. Recent developments reveal that several disturbing trends are building in the regulatory environment. Two of them are explored in this paper.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"208 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1997-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116226496","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 : 1997-04-20DOI: 10.1109/CITCON.1997.599412
C. Petrus
The measurement of the flame temperature and burning zone conditions in cement kilns has long been considered absolutely critical in maintaining optimum clinker production levels. This process control has evolved over the years; from the well-trained eye of a seasoned kiln burner to the dual imaging pyrometry technology used to continually monitor cement kiln burning zones. This device easily integrates into any of today's sophisticated control systems, and quickly becomes a critical link in establishing a control strategy for kiln operation. This paper spotlights the installation and operation of three Spyrometer/sup TM/ systems at Medusa's Wampum facility (USA) during the plant's 1995 automation project. The camera's microprocessors link directly to the remote I/O racks of the new PLC-based control system. So they not only provide a continual window into all three burning zones, but they monitor six temperatures at operator specified windows. These inputs can also be used as a BIF regulated waste fuel interlock or as an expert system control parameter. The data generated from the pyrometer's temperature measurement can also be used in an effective clinker quality control program. By coupling clinker microscopy and cement physical testing with the trended data, tangible performance improvements are demonstrated for not only the product, but with the process operation.
{"title":"Integration of imaging pyrometry into the Wampum Plant automation project [cement plant]","authors":"C. Petrus","doi":"10.1109/CITCON.1997.599412","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599412","url":null,"abstract":"The measurement of the flame temperature and burning zone conditions in cement kilns has long been considered absolutely critical in maintaining optimum clinker production levels. This process control has evolved over the years; from the well-trained eye of a seasoned kiln burner to the dual imaging pyrometry technology used to continually monitor cement kiln burning zones. This device easily integrates into any of today's sophisticated control systems, and quickly becomes a critical link in establishing a control strategy for kiln operation. This paper spotlights the installation and operation of three Spyrometer/sup TM/ systems at Medusa's Wampum facility (USA) during the plant's 1995 automation project. The camera's microprocessors link directly to the remote I/O racks of the new PLC-based control system. So they not only provide a continual window into all three burning zones, but they monitor six temperatures at operator specified windows. These inputs can also be used as a BIF regulated waste fuel interlock or as an expert system control parameter. The data generated from the pyrometer's temperature measurement can also be used in an effective clinker quality control program. By coupling clinker microscopy and cement physical testing with the trended data, tangible performance improvements are demonstrated for not only the product, but with the process operation.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"33 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1997-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128520966","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 : 1997-04-20DOI: 10.1109/CITCON.1997.599185
B. Andersen
This paper discusses the evolution in technology which has led to today's Power Management Control System facility automation systems. A summary of current, "state-of-the-art" functionality within the different component, network and software categories that make up PMCS systems is provided. This will enable the readers to begin to identify their companies' own PMCS needs, explore the expected economic benefits and interact with prospective suppliers regarding their capabilities. We cover some worst case outage scenarios for which these systems can serve to prevent or minimize the effects of. The following components are discussed: circuit beakers; relays; power meters; and controllers.
{"title":"Power Management Control Systems-more than energy savings","authors":"B. Andersen","doi":"10.1109/CITCON.1997.599185","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599185","url":null,"abstract":"This paper discusses the evolution in technology which has led to today's Power Management Control System facility automation systems. A summary of current, \"state-of-the-art\" functionality within the different component, network and software categories that make up PMCS systems is provided. This will enable the readers to begin to identify their companies' own PMCS needs, explore the expected economic benefits and interact with prospective suppliers regarding their capabilities. We cover some worst case outage scenarios for which these systems can serve to prevent or minimize the effects of. The following components are discussed: circuit beakers; relays; power meters; and controllers.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"11 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1997-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132937734","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 : 1997-04-20DOI: 10.1109/CITCON.1997.599241
S. Simonye, L. Alpena, G. Witte
The Lafarge Cement Plant in Alpena, MI produces 2.5 million tons of cement per year from 5 kilns which each yield around 1250 tons per day. Plant control is distributed over forty PLC5s with over eighteen thousand I/O points, which have been installed over ten years. The kilns were the last major pieces of equipment yet to be tied into the PLC based supervisory system. PLC5s were chosen for the kiln automation based on this installed base and on the ease of expanding the existing supervisory system network to accommodate the kiln control. The plant architecture uses three layers of communication: first, remote I/O to communicate to the I/O subsystem from the PLC Processor; and secondly, a Data Highway Plus to communicate between processors and to the Ethernet gateway/data server. This gateway provides process data to the third layer, the process supervisory network. The process supervisory network consists of supervisory workstations running Intellution DMACs and the expert system LUCIE which is Lafarge's own application running on Gensym G2. This paper discusses the design and installation of a DeviceNet communication network to smart motor control centers (MCCs) on the three kilns at the Alpena plant. The DeviceNet link, which provides direct digital control and monitoring of motors, is linked to the supervisory system via the remote I/O link.
{"title":"Applying DeviceNet in motor control centers at a cement plant","authors":"S. Simonye, L. Alpena, G. Witte","doi":"10.1109/CITCON.1997.599241","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599241","url":null,"abstract":"The Lafarge Cement Plant in Alpena, MI produces 2.5 million tons of cement per year from 5 kilns which each yield around 1250 tons per day. Plant control is distributed over forty PLC5s with over eighteen thousand I/O points, which have been installed over ten years. The kilns were the last major pieces of equipment yet to be tied into the PLC based supervisory system. PLC5s were chosen for the kiln automation based on this installed base and on the ease of expanding the existing supervisory system network to accommodate the kiln control. The plant architecture uses three layers of communication: first, remote I/O to communicate to the I/O subsystem from the PLC Processor; and secondly, a Data Highway Plus to communicate between processors and to the Ethernet gateway/data server. This gateway provides process data to the third layer, the process supervisory network. The process supervisory network consists of supervisory workstations running Intellution DMACs and the expert system LUCIE which is Lafarge's own application running on Gensym G2. This paper discusses the design and installation of a DeviceNet communication network to smart motor control centers (MCCs) on the three kilns at the Alpena plant. The DeviceNet link, which provides direct digital control and monitoring of motors, is linked to the supervisory system via the remote I/O link.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"28 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1997-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114480967","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 : 1997-04-20DOI: 10.1109/CITCON.1997.602010
E. Sulzer, M. Bertsch
Various cement plants use the definition of process control system for their installed operator control stations (also called man-machine interfaces or MMI). One can find many control islands which are linked together with the aid of more or less intelligent solutions. Today, a modern state-of-the-art process control system is the heart of the plant. The system provides the necessary information in order for management to monitor quality and efficiency of the production, as well as the profitability of the plant. The selection of the process control system will influence the plant's design, personnel structure and manpower. A modern process control system must support the customer's goal to reduce the amount of instrumentation and process equipment. This paper gives some ideas on how to select and implement a modern process control system.
{"title":"Design and engineering of a modern process control system ~for cement plants","authors":"E. Sulzer, M. Bertsch","doi":"10.1109/CITCON.1997.602010","DOIUrl":"https://doi.org/10.1109/CITCON.1997.602010","url":null,"abstract":"Various cement plants use the definition of process control system for their installed operator control stations (also called man-machine interfaces or MMI). One can find many control islands which are linked together with the aid of more or less intelligent solutions. Today, a modern state-of-the-art process control system is the heart of the plant. The system provides the necessary information in order for management to monitor quality and efficiency of the production, as well as the profitability of the plant. The selection of the process control system will influence the plant's design, personnel structure and manpower. A modern process control system must support the customer's goal to reduce the amount of instrumentation and process equipment. This paper gives some ideas on how to select and implement a modern process control system.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"76 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1997-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114137208","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 : 1997-04-20DOI: 10.1109/CITCON.1997.599275
J. Sellon
Nikola Tesla was perhaps the greatest inventor/engineer the world has known since the time of Leonardo da Vinci. Similar to da Vinci, Tesla's work was revolutionary, and Tesla's work was forgotten by the time his work was fully developed by others. Tesla was awarded the original patents that established the foundation for generating, delivering and utilizing the electricity used in the cement industry. Other patents of Tesla established the foundation for monitoring and controlling the equipment used in modern cement plants. In addition to the impact on the production facilities, the demand for cement increased worldwide as a result of Tesla's patents. Finally, Tesla's life work provides inspiration for those who are solving the technical challenges that the cement industry faces today and will face tomorrow.
{"title":"The impact of Nikola Tesla on the cement industry","authors":"J. Sellon","doi":"10.1109/CITCON.1997.599275","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599275","url":null,"abstract":"Nikola Tesla was perhaps the greatest inventor/engineer the world has known since the time of Leonardo da Vinci. Similar to da Vinci, Tesla's work was revolutionary, and Tesla's work was forgotten by the time his work was fully developed by others. Tesla was awarded the original patents that established the foundation for generating, delivering and utilizing the electricity used in the cement industry. Other patents of Tesla established the foundation for monitoring and controlling the equipment used in modern cement plants. In addition to the impact on the production facilities, the demand for cement increased worldwide as a result of Tesla's patents. Finally, Tesla's life work provides inspiration for those who are solving the technical challenges that the cement industry faces today and will face tomorrow.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"119 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1997-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123250167","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 : 1997-04-20DOI: 10.1109/CITCON.1997.599298
M. Ito, K. Sato, Y. Naoi
The specific power consumption, product quality and other performance of the "OK" and "CK" vertical roller mills for cement grinding are briefly stated. Hence, the enhancement in increasing the productivity of the vertical roller mill at Chichibu Onoda Cement Corporation (COCC) is introduced. These include: (a) restoring a table liner and roller tires by hard-facing to reduce maintenance costs; (b) increasing the air flow rate through the roller mill to improve the production rate; (c) installing the separator outside the roller mill to reduce specific power consumption; and (d) implementing automatic on-line control of cement fineness to reduce personnel costs and stabilize product quality.
{"title":"Productivity increase of the vertical roller mill for cement grinding","authors":"M. Ito, K. Sato, Y. Naoi","doi":"10.1109/CITCON.1997.599298","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599298","url":null,"abstract":"The specific power consumption, product quality and other performance of the \"OK\" and \"CK\" vertical roller mills for cement grinding are briefly stated. Hence, the enhancement in increasing the productivity of the vertical roller mill at Chichibu Onoda Cement Corporation (COCC) is introduced. These include: (a) restoring a table liner and roller tires by hard-facing to reduce maintenance costs; (b) increasing the air flow rate through the roller mill to improve the production rate; (c) installing the separator outside the roller mill to reduce specific power consumption; and (d) implementing automatic on-line control of cement fineness to reduce personnel costs and stabilize product quality.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"10 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1997-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126857212","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 : 1997-04-20DOI: 10.1109/CITCON.1997.599162
G. Stone, J. Kapler
Partial discharge (PD) tests can determine which motor and generator stator windings are experiencing insulation problems. A deteriorated winding has a PD activity which can be 30 times or more higher than a winding in good condition. This great difference in PD activity enables even nonspecialized maintenance personnel to identify the few motors or generators in a company which need further investigation and/or maintenance. After implementing on-line partial discharge tests companies can often confidently extend the outage between major machine inspections. This saves on outage costs and reduces the risk of a stator fault due to human error during maintenance. Finally, on older machines, if there has been no increase in partial discharge activity over time, then the life of the stator winding can be confidently extended, saving a considerable capital expenditure. The PD tests discussed cost virtually nothing to perform, once the sensors are installed, since existing company staff can do the tests in about 30 minutes during normal motor or generator operation.
{"title":"Using partial discharge measurement technology to implement predictive maintenance in high voltage motor and generator stator windings","authors":"G. Stone, J. Kapler","doi":"10.1109/CITCON.1997.599162","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599162","url":null,"abstract":"Partial discharge (PD) tests can determine which motor and generator stator windings are experiencing insulation problems. A deteriorated winding has a PD activity which can be 30 times or more higher than a winding in good condition. This great difference in PD activity enables even nonspecialized maintenance personnel to identify the few motors or generators in a company which need further investigation and/or maintenance. After implementing on-line partial discharge tests companies can often confidently extend the outage between major machine inspections. This saves on outage costs and reduces the risk of a stator fault due to human error during maintenance. Finally, on older machines, if there has been no increase in partial discharge activity over time, then the life of the stator winding can be confidently extended, saving a considerable capital expenditure. The PD tests discussed cost virtually nothing to perform, once the sensors are installed, since existing company staff can do the tests in about 30 minutes during normal motor or generator operation.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"34 5","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1997-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"113972201","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 : 1997-04-20DOI: 10.1109/CITCON.1997.599168
M. Holland, M. von Seebach, W. Ranze
The concept of an energy efficient integral grinding system incorporating a roller press is best served with variable speed drives. This drive system is required to accommodate grinding of different types of cement with different fineness. It eases the load on the mechanical components and is an economically feasible drive providing a return of investment of approximately one year. Since the variable speed drive system incorporates proven standard components, it is also extremely reliable.
{"title":"Variable speed drives for roller presses","authors":"M. Holland, M. von Seebach, W. Ranze","doi":"10.1109/CITCON.1997.599168","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599168","url":null,"abstract":"The concept of an energy efficient integral grinding system incorporating a roller press is best served with variable speed drives. This drive system is required to accommodate grinding of different types of cement with different fineness. It eases the load on the mechanical components and is an economically feasible drive providing a return of investment of approximately one year. Since the variable speed drive system incorporates proven standard components, it is also extremely reliable.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"126 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1997-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123080122","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 : 1997-04-20DOI: 10.1109/CITCON.1997.599411
C. Ruby
Expert system kiln control is proven technology. The expert system's smoother control provides significant operating cost reductions by: (1) lowering the specific consumption (i.e. MBTU/tons clinker or kcal/kg); (2) extending brick life; (3) lowering electrical energy costs; (4) lowering maintenance costs; (5) substantially reducing the use of high price auxiliary fuels such as gas; and (6) kiln NO/sub x/ levels are controlled, addressing stack emission and environmental regulation requirements. This paper describes the approach selected for kiln expert control for the Hercules cement pre-calciner kiln project, USA. The goals were full functionality expert control that focused on the issues of ease of use and the high costs of kiln expert control. This paper is divided into four sections. The first section provides an overview of kiln expert control system functionality, the second section describes the project goals, the third section describes the new expert system approach and the fourth section discusses risk management and project results.
{"title":"A new approach to expert kiln control","authors":"C. Ruby","doi":"10.1109/CITCON.1997.599411","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599411","url":null,"abstract":"Expert system kiln control is proven technology. The expert system's smoother control provides significant operating cost reductions by: (1) lowering the specific consumption (i.e. MBTU/tons clinker or kcal/kg); (2) extending brick life; (3) lowering electrical energy costs; (4) lowering maintenance costs; (5) substantially reducing the use of high price auxiliary fuels such as gas; and (6) kiln NO/sub x/ levels are controlled, addressing stack emission and environmental regulation requirements. This paper describes the approach selected for kiln expert control for the Hercules cement pre-calciner kiln project, USA. The goals were full functionality expert control that focused on the issues of ease of use and the high costs of kiln expert control. This paper is divided into four sections. The first section provides an overview of kiln expert control system functionality, the second section describes the project goals, the third section describes the new expert system approach and the fourth section discusses risk management and project results.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"15 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1997-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121843575","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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