The automation evolution on the threshold of a new era [cement industry]

Although good quality cement has been made long before the advent of the first bit and byte, globalization of the cement market, increased production capacity and the need for consistent high quality product has fueled the demand to incorporate the high-technology explosion into plant operations. As plant automation has evolved and practical experience has grown, cement manufacturers have developed the savvy to discern between wishes and needs and to differentiate between slick and substance. Automation systems must help them work smarter-optimize fuel and power consumption, maximize production, reduce wear on the refractory, minimize unplanned shutdowns, better utilize personnel and resources while insuring product consistency and quality. There was a time when automation, computers, PLCs and communication protocols were daunting subjects best relegated to contracted experts. Hardware was proprietary, software and communication protocols even more so. All this served to severely limit expansion and flexibility, often defeating the benefits of automation. Automation requirements are now better defined and demand commonality of parts, standard communications and hardware, modularity and system flexibility and expandability.