Pub Date : 1997-04-20DOI: 10.1109/CITCON.1997.599175
L. Manz, J. Oldenkamp
In a cement mill there are applications that require high starting torques like draft inducer fans and ball mills. Sometimes a larger motor is required just to give enough starting torque to accelerate the load. This paper reviews how adjustable speed drives can be used to give high starting torque on a motor sized for running torque, not starting torque, with a side benefit of low starting current. This allows the user to install a smaller motor-one sized for running the load, not starting it-and gives adjustable speed capability for process flow control and speed control. While accelerating high starting torque loads is the subject of this paper, the same principles can be used to maximize the starting torque with a certain drive size (maximum torque for a given amps rating of the ASD).
{"title":"Starting high inertia loads on adjustable speed drives","authors":"L. Manz, J. Oldenkamp","doi":"10.1109/CITCON.1997.599175","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599175","url":null,"abstract":"In a cement mill there are applications that require high starting torques like draft inducer fans and ball mills. Sometimes a larger motor is required just to give enough starting torque to accelerate the load. This paper reviews how adjustable speed drives can be used to give high starting torque on a motor sized for running torque, not starting torque, with a side benefit of low starting current. This allows the user to install a smaller motor-one sized for running the load, not starting it-and gives adjustable speed capability for process flow control and speed control. While accelerating high starting torque loads is the subject of this paper, the same principles can be used to maximize the starting torque with a certain drive size (maximum torque for a given amps rating of the ASD).","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"62 11","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1997-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114050295","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.1997.599299
G. Marchal
Comminution is an important element for cost evaluation in any cement plant, mainly in relation to the power consumed, which is about 80 to 90 kW for a cement plant. In the early 90s, grinding in cement plants was operated mainly by vertical mills for raw material with rather good results in the majority of cases, and by tube mills for cement, with some development of mixed grinding with roller presses completing tube mills, with a result not as reliable however better for energy. HOROMILL/sup R/ has introduced in this field an entirely new grinding process to reduce energy consumption with an original design, for both cement and raw grinding. We explain the principle of this mill, why this principle saves energy, and then show the industrial results obtained in the first big mills installed at the CIMENTAS plant, DARICA, KARSDORF as well as the other plants currently commissioned.
{"title":"Industrial experience with clinker grinding in the HOROMILL/sup R/","authors":"G. Marchal","doi":"10.1109/CITCON.1997.599299","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599299","url":null,"abstract":"Comminution is an important element for cost evaluation in any cement plant, mainly in relation to the power consumed, which is about 80 to 90 kW for a cement plant. In the early 90s, grinding in cement plants was operated mainly by vertical mills for raw material with rather good results in the majority of cases, and by tube mills for cement, with some development of mixed grinding with roller presses completing tube mills, with a result not as reliable however better for energy. HOROMILL/sup R/ has introduced in this field an entirely new grinding process to reduce energy consumption with an original design, for both cement and raw grinding. We explain the principle of this mill, why this principle saves energy, and then show the industrial results obtained in the first big mills installed at the CIMENTAS plant, DARICA, KARSDORF as well as the other plants currently commissioned.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"61 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":"132609731","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.1997.599369
R. Vidergar, D. Rapson, S. Dhanjal
Precessing jet burner technology has been applied to a number of process industries that burn natural gas in rotary kilns with remarkable results. This is the first time that precessing jet technology has been incorporated into a burner firing pulverized coal. This paper discusses some of the design considerations and presents plant data from a four stage preheater cement kiln showing increased production, improved fuel consumption and the NO/sub x/ reduction achieved.
{"title":"Gyro-therm technology boosts cement kiln output, efficiency and cuts NO/sub x/ emissions","authors":"R. Vidergar, D. Rapson, S. Dhanjal","doi":"10.1109/CITCON.1997.599369","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599369","url":null,"abstract":"Precessing jet burner technology has been applied to a number of process industries that burn natural gas in rotary kilns with remarkable results. This is the first time that precessing jet technology has been incorporated into a burner firing pulverized coal. This paper discusses some of the design considerations and presents plant data from a four stage preheater cement kiln showing increased production, improved fuel consumption and the NO/sub x/ reduction achieved.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"1 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":"131236701","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.1997.599302
H. Brundiek, H. Poeschl
Vertical roller mills are known to be excellent drying machines. This is due to the fact, that the grinding material is in contact with the hot gas during the grinding and classification process. Considering critical physical and technical aspects, a stable operation of a grinding plant can be achieved even for raw materials with more than 20% of feed moisture without a pre-drying-system. The authors discuss the throughput parameters for a cement roller mill, the lay-out and sizing of the mill, materials selection, the mill gear reducer, industrial application, the raw material feeding system, and operation of the plant.
{"title":"Roller mill application for high moisture feed","authors":"H. Brundiek, H. Poeschl","doi":"10.1109/CITCON.1997.599302","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599302","url":null,"abstract":"Vertical roller mills are known to be excellent drying machines. This is due to the fact, that the grinding material is in contact with the hot gas during the grinding and classification process. Considering critical physical and technical aspects, a stable operation of a grinding plant can be achieved even for raw materials with more than 20% of feed moisture without a pre-drying-system. The authors discuss the throughput parameters for a cement roller mill, the lay-out and sizing of the mill, materials selection, the mill gear reducer, industrial application, the raw material feeding system, and operation of the plant.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"37 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":"115468315","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.1997.601995
M. Rose
In 1991, the cement companies in eastern Pennsylvania suffered from a poor economy and strong competition within the marketplace. The Lafarge Whitehall plant was no exception and endeavored to become more profitable through cost reduction. Rigorous analysis of both corporate and cement industry costs revealed that the plant power costs were excessive compared to industry standards. In fact, the plant had the highest power costs of all Lafarge North American plants. This paper gives a history of cost saving measures and results thereof. The two major areas identified for improvement were the power contract and power utilization efficiency. The plant initiated power contract negotiations with Pennsylvania Power and Light Company (PP&L) in 1992, which concluded with a new interruptible power contract in August of that year. The contract guaranteed lower demand and energy rates, yet subjected the customer to power curtailments. With the interruptible contract in place, the various components of the contract were analyzed for additional cost savings. Primary measures taken included production schedule optimization and careful utilization of production equipment during on-peak hours. Diesel generators were installed in 1995 to provide an alternate source of power during curtailments, lessening the burden on the utility to guarantee costly firm demand levels. As a result, the 1996 plant power costs were reduced by 40.6% from 1991 costs.
{"title":"Power costs reduction measures at Lafarge Whitehall plant","authors":"M. Rose","doi":"10.1109/CITCON.1997.601995","DOIUrl":"https://doi.org/10.1109/CITCON.1997.601995","url":null,"abstract":"In 1991, the cement companies in eastern Pennsylvania suffered from a poor economy and strong competition within the marketplace. The Lafarge Whitehall plant was no exception and endeavored to become more profitable through cost reduction. Rigorous analysis of both corporate and cement industry costs revealed that the plant power costs were excessive compared to industry standards. In fact, the plant had the highest power costs of all Lafarge North American plants. This paper gives a history of cost saving measures and results thereof. The two major areas identified for improvement were the power contract and power utilization efficiency. The plant initiated power contract negotiations with Pennsylvania Power and Light Company (PP&L) in 1992, which concluded with a new interruptible power contract in August of that year. The contract guaranteed lower demand and energy rates, yet subjected the customer to power curtailments. With the interruptible contract in place, the various components of the contract were analyzed for additional cost savings. Primary measures taken included production schedule optimization and careful utilization of production equipment during on-peak hours. Diesel generators were installed in 1995 to provide an alternate source of power during curtailments, lessening the burden on the utility to guarantee costly firm demand levels. As a result, the 1996 plant power costs were reduced by 40.6% from 1991 costs.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"1 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":"123030526","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.1997.599153
R.A. Errath
Trends indicate that variable speed AC drives are already well established in the cement industry. However, as the use of these low maintenance drives, becomes more widespread, so do the associated problems. One such problem is that of electromagnetic interference (EI). EI can lead to de-rating when dimensioning the motor and modification of installation practices. In fact the need to take EI into consideration is no longer just recommended, it is rapidly becoming imperative. This paper deals with the background to these problems. Advice is also given on what is important for AC variable speed drive installation, plus recommendations are given to potential purchasers of AC drive systems.
{"title":"EMC on AC motors-advice, tips and hints","authors":"R.A. Errath","doi":"10.1109/CITCON.1997.599153","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599153","url":null,"abstract":"Trends indicate that variable speed AC drives are already well established in the cement industry. However, as the use of these low maintenance drives, becomes more widespread, so do the associated problems. One such problem is that of electromagnetic interference (EI). EI can lead to de-rating when dimensioning the motor and modification of installation practices. In fact the need to take EI into consideration is no longer just recommended, it is rapidly becoming imperative. This paper deals with the background to these problems. Advice is also given on what is important for AC variable speed drive installation, plus recommendations are given to potential purchasers of AC drive systems.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"767 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":"123280350","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.1997.599364
N. Biege, H. Pretti, W. Pirwitz
The global cement industry handles billions of tons of dusty material (raw meal and cement) each year and does a good job of keeping dust out of the atmosphere. Over the years, the allowable dust emissions from cement plants have become lower and lower. This paper discusses and compares the different methods of removing dust particles from the exhaust gases of cement processes. It is focused on the removal of solid dust particles from the vent systems of cement kilns, raw mills, clinker coolers, finish mills and finish mill high efficiency separators with emphasis on the largest dust collector in the plant: the kiln and raw mill dust collector.
{"title":"Emerging and competing technologies for particulate control in cement plants","authors":"N. Biege, H. Pretti, W. Pirwitz","doi":"10.1109/CITCON.1997.599364","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599364","url":null,"abstract":"The global cement industry handles billions of tons of dusty material (raw meal and cement) each year and does a good job of keeping dust out of the atmosphere. Over the years, the allowable dust emissions from cement plants have become lower and lower. This paper discusses and compares the different methods of removing dust particles from the exhaust gases of cement processes. It is focused on the removal of solid dust particles from the vent systems of cement kilns, raw mills, clinker coolers, finish mills and finish mill high efficiency separators with emphasis on the largest dust collector in the plant: the kiln and raw mill dust collector.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"3 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":"116916101","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 : 1900-01-01DOI: 10.1109/CITCON.1997.601998
B. Gunnarson
A unique marine cement import terminal has recently been taken into operation in Singapore. The terminal introduces a new cement import concept to the industry. The large, state-of-the-art terminal is owned by the Port and used by many independent cement companies. The design of the terminal is further described in this paper.
{"title":"State-of-the-art marine cement terminals","authors":"B. Gunnarson","doi":"10.1109/CITCON.1997.601998","DOIUrl":"https://doi.org/10.1109/CITCON.1997.601998","url":null,"abstract":"A unique marine cement import terminal has recently been taken into operation in Singapore. The terminal introduces a new cement import concept to the industry. The large, state-of-the-art terminal is owned by the Port and used by many independent cement companies. The design of the terminal is further described in this paper.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"181 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1900-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132965080","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 : 1900-01-01DOI: 10.1109/CITCON.1997.599139
U. Ruesch
Repeatedly transient (brief) undervoltages give rise to production losses which could be avoided in many cases. Transient over- and undervoltages are part of every electricity supply system. The article describes how the various kinds of undervoltage originate and introduces a classification system which should simplify communication for further discussion. Precautions that can be taken by consumers to permit operation as free as possible from disturbance in spite of undervoltages, are explained. Closer attention is paid to high-voltage motors which are fed direct from the system because here the possible means of exerting an influence are smallest and, on the other hand, serious electrical and mechanical damage could occur in the event of a fault. The undervoltage ride-through capabilities of the various large variable speed drive systems are commented upon. In conclusion a mode of proceeding is described, showing how to identify, localise and eliminate components sensitive to undervoltage.
{"title":"Transient undervoltages in the electricity supply system and their consequences in cement plants","authors":"U. Ruesch","doi":"10.1109/CITCON.1997.599139","DOIUrl":"https://doi.org/10.1109/CITCON.1997.599139","url":null,"abstract":"Repeatedly transient (brief) undervoltages give rise to production losses which could be avoided in many cases. Transient over- and undervoltages are part of every electricity supply system. The article describes how the various kinds of undervoltage originate and introduces a classification system which should simplify communication for further discussion. Precautions that can be taken by consumers to permit operation as free as possible from disturbance in spite of undervoltages, are explained. Closer attention is paid to high-voltage motors which are fed direct from the system because here the possible means of exerting an influence are smallest and, on the other hand, serious electrical and mechanical damage could occur in the event of a fault. The undervoltage ride-through capabilities of the various large variable speed drive systems are commented upon. In conclusion a mode of proceeding is described, showing how to identify, localise and eliminate components sensitive to undervoltage.","PeriodicalId":443254,"journal":{"name":"1997 IEEE/PCA Cement Industry Technical Conference. XXXIX Conference Record (Cat. No.97CH36076)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1900-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130931726","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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