Advanced process control of kilns in the cement industry. It is based on the latest developments fuzzy logic and modelbased predictive control. Table of contents technical eia guidance manual for cement industry september 2009 i table of contents 1. The paper deals with control in the cement manufacturing. Process modeling and controller tuning based on loop shaping procedures 157 brazilian journal of chemical engineering vol. Application of statistical process control spc in manufacturing industry in a developing country. Our commitment to quality performance is demonstrated by our rigorous adherence to the lafarge quality technical standard and iso 9000 series certification. In industry, suppliers are required to provide evidence of statistical process control to their customers. Mineralogy of raw material used for manufacturing of cement. Oct 10, 2015 control of portland cement quality, first edition 2007 by c. Quality assurance of cement from production to construction.
The larger existing kiln in a wet process plant produces 3600 tonnes of clinker per day. Of the process industries which are energy intensive, the cement industry has much to gain in applying this new technology. This requires the analysis of relevant elements in raw materials. The environmental im pact of the cement production and its variations between different cement plants, using life. Ppt cement industry powerpoint presentation free to. Aug 30, 2012 cement manufacturing process phase iv. New technique be developed to proper control cement manufacturing process. Pdf application of statistical process control spc in. A reliable determination of the carbon and sulphur content in cement is an essential part of the quality control process.
Abb process control solutions for cement plants abb. Accurate cement production also depends on belt scale systems to monitor output and inventory or regulate product loadout, as well as tramp metal detectors to protect equipment and keep the operation running. The manufacture of cement by wet process is energy intensive and thus uneconomical as compared to dry process and semi dry process. Cement is a greenish grey colored powder, made of calcined mixtures of clay and limestone. Also a complete solution for rotary kiln and calciner. International journal of information technology, control and automation ijitca vol. Wet process, semidry process, dry process and finish process. Hailstone technical director general portland cement company dallas, texas. This reference document on best available techniques in the cement and lime industries reflects an information exchange carried out according to article 162 of council directive 9661ec. Read pgnaa improves process and quality control in cement production to learn what makes pgnaa particularly suited for cement analysis. Advanced process control apc using straightforward design and deployment of model predictive control mpc with system 800xa dcs enables higher level of automation and optimization of rotary cement kilns and mills, alternative fuel management and material blending.
Reliable process and quality control in cement production by edxrf astm c114 introduction these days cement is produced in a highly optimized, continuous process. Which is indias largest cement plant the cement industry is one of the prominent industries in india. Output from the cement industry is directly related to the state of the construction business in general and therefore tracks the overall economic situation closely. This temperature begins a chemical reaction so called decarbonation. Each process is explained chemical reactions for manufacture of portland cement. The use of modern, gravimetric solid fuel feed systems. Air pollution control in the cement industry in discussing air pollution control within the cement industry, we will touch upon the following. The carbon content is usually certified as co2 and sulphur content is given as so3. Spc is a proven technique for determining the process capability and predicting the yield from a process. In this reaction material like limestone releases the carbon dioxide. Operator limits advanced process control operator vs computerbased decisions. Here, local authorities often offer subsidies for waste processing, bringing added economic benefits to the cement plant operations. Development trend and key points of cement grinding process.
Standard control modules are tailored and integrated to ensure ease of operation and simple maintenance. Comparison of size distribution on separator product. Control of portland cement quality, first edition 2007 by c. Process control applications are implemented with functionoriented software modules specifi. Instrumentation for cement plants systems and solutions. Process control for the cement industry digital asset management. These measures are usually taken to improve clinker.
This book is an important reference for plant managers and quality control personnel. Portland cement is a fine, typically gray powder comprised of calcium from lime, silicates, aluminates argillaceous, and ferrites, with addition of sulfates. Intelligent control in the cement industry sciencedirect. The remainder of this report is organized as follows. Cement making is essentially a chemical process industry and has much in. Abb process control solutions for cement plants abb process.
Chapter 3 provides a process description and industry characterization of cement manufacturing. The cement industry recognizes its responsibility to manage the environmental impact, associated with the manufacturing of its product. The aim of this document is to provide background information on the cement industry and cement manufacturing technology, and to determine best available techniques for the installations for production of cement. The limestone is excavated from open cast mines after drilling and blasting and loaded onto dumpers. Flsmidths ecsprocessexpert provides advanced process control and optimization for cement plants. He developed the concept of control with regard to variation, and came up with statistical process control charts which provide a simple. With cement production processes consuming such a large amount of energy, the opportunity is clear for cement plant operators to introduce alternative fuels coprocessing to their combustion and production processes. You need a good deal of reasonably pure limestone or marble of chalk or othe form of caco3. The kiln has to operate continuously in order to ensure a steady regime, and therefore uniformity of clinker. A risk assessment study on occupational hazards in cement. Manufacture of portland cement materials and process. Pdf advanced control schemes for cement fabrication processes. Process engineering training program module 6 process control in the cement. Competence for the processes in the cement industry 6 the cement industry typically produces portland cement sometimes also masonry cement.
Process control and automation solutions for cement and glass plants. Cement producers have faced a significant rise in energy costs with the introduction of dryprocess kilns, with a record average consumption of 100200 kwh per ton of cement, according to the 2009 cement plant operations handbook. Pid controllers regulating the quality of cement raw optimizing the control system of cement milling. Preheating and precalcination to the extent possible, considering the existing kiln system. Introduction to statistical process control techniques. General information about the cement industry 2 environmental.
Environmental impact assessment guidelines for cement. Implementation of cement industry day by day to increase the productivity beneficial for our future. The control strategies in ecsprocessexpert are based on four decades of experience in cement control and optimization projects. The process data collected from a local plant, cimentas cement factory, in. Kiln is a huge rotating furnace also called as the heart of cement making process. Modernization of process control systems in cement plants english pdf article. In the second part of the study, a quantitative procedure for monitoring and evaluating cement milling process performance was described. Aug 25, 2011 cement producers have faced a significant rise in energy costs with the introduction of dry process kilns, with a record average consumption of 100200 kwh per ton of cement, according to the 2009 cement plant operations handbook. The document has to be seen in the light of the preface which describes the objectives of the document and its use. Industrial practice shows that the method of choice for design of robust advanced process control and optimizaadvanced process control to meet the needs of the metallurgical industry. Description of the cement manufacturing process cement is a finely ground powder which, when mixed with water, forms a hardening paste of calcium silicate hydrates and calcium aluminate hydrates. Our awardwinning process control solutions provide easy single window access to the process, production, quality and business information from the most remote location to corporate headquarters.
When mixed with water becomes a hard and strong building material. The cement manufacturing process starts from the mining of raw materials that are used in cement manufacturing, mainly limestone and clays. I have studied the incident reports of past few years and also the process involved in the manufacturing of cement. Portland cement manufacturing plants both old and new located in congested and sparsely populated areas of the country have, for many years, installed the most modern and efficient emission control. Quality control of cement knowledge base applications.
Pdf process automation of cement plant international. Continuous gas analyzer system is the perfect fitting solution for emission monitoring, process gas measurements and specific applications in the cement industry. Elemental analysis and phase analysis information, both from the thermo scientific xray analyzer, enables the cement producer to monitor, adjust and optimize the process for quality. They can be supplied by abbs global network of skilled control. The emission limit values shall be set by national authorities based on best available techniques for the relevant industrial sector. Integrated pollution prevention and control ippc reference. The foundation for statistical process control was laid by dr. The preparation of cement includes mining, crushing, and grinding of raw materials, calcining the materials in 1408. For a process to be adequately controlled and manipulated, the variable of interest in the process e. Cement industry, computer control, adaptive control, stochastic control, process identification contents 1.
The solution cement quant therefore offers well selected certified reference materials and guarantees accurate results. A discussion of uncontrolled no x emission levels is presented in chapter 4. In order to maintain a constant product quality, each of the various production steps must be carefully controlled. The cement industry is an energy intensive industry with energy typically accounting for about 40 % of operational costs, i. Walter shewart working in the bell telephone laboratories in the 1920s conducting research on methods to improve quality and lower costs. To proper continuous improvement of production process. Many cement plants have adopted general primary measures, such as process control optimisation, use of modern, gravimetric solid fuel feed systems, optimised cooler connections and use of power management systems. More than 30 raw materials are known to be used in the manufacture of portland cement, and these.
Its product can be found almost everywhere in the everyday life, and the industrial society cannot survive without cement. Mainly, there are two types of cement production process. Alternative control techniques document nox emissions from. List of machinery and process equipment technical information such as capacity and expected hours of operation and operational control measures emissions data.
Internal audit in cement industry contd 2 first cement produced by romans and greeks with ash mix and lime 3 portland cement developed by england in early 18 century 4 cement industry plays a vital role in indian economys and gdp growth, directly and indirectly through infrastructure, manufacturing and every other connected. Building on long experience, we use industrialit technology and customize process control solutions to meet your exact needs. Transmitters used in process instrumentation learning. Alternative control techniques and achievable controlled emission. Manufacturing of cement involves various raw materials and processes.
Temperature, pressure or flow often called the process variable pv needs to be measured by a sensor which converts the measurement into a suitable signal format 4 20ma or digital and then transmit it to a controller which makes the control decision and finally acts on a final. In the cement grinding process, in addition to the tube mill process, the roller presses which were introduced in germany in the mid1980s were mainly used for pregrinding of cement raw materials and cement clinker, that is, semifinal grinding. I have studied the incident reports of past few years and also the process involved in. Bangpedersencomplete chemical control of the cement plant processes. A limestone quarry is inside the plant area and a clays quarry is as far from the plant area as 25 km. If the sulphur content is too high, the cement could be destroyed as a result of the chemical reaction of sulphuric acid. They play a pivotal role in the overall indian economy. Geographic concentration of manufacturing plants b. Cement manufacturing process phases flow chart cement. Cement and glass makers need integrated process control systems that can improve plantwide efficiency and productivity. Deva cement plant was established in 1972 and its operation started in 1976. Intelligent control is offering new possibilities for improvements in efficiency and productivity in process automation. It describes the cement production process and its emission sources followed by overview of emissions and their environmental and health impacts.