2011 IEEE-IAS/PCA 53rd Cement Industry Technical Conference

22-26 May 2011

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  • [Title page]

    Publication Year: 2011, Page(s): 1
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  • [Copyright notice]

    Publication Year: 2011, Page(s): 1
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  • Considerations in network and automation options for Low-Voltage Motor Control Centers

    Publication Year: 2011, Page(s):1 - 14
    Cited by:  Papers (1)
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (1377 KB) | HTML iconHTML

    The wide spread utilization of industrial communication networks in industrial applications for Low-Voltage Motor Control Centers (LV MCC's) started in 1995 when Open DeviceNet Vendors Association (ODVA) was formed and an open standard for DeviceNet was developed. The main value proposition behind networks was wire savings and reduction of downtime, both quantifiable and tangible benefits, as well... View full abstract»

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  • Network infrastructure in large, integrated control systems

    Publication Year: 2011, Page(s):1 - 7
    Cited by:  Papers (3)
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (105 KB) | HTML iconHTML

    Modern integrated control systems have become a blend of traditional process automation and functions that have in the past only been found in IT departments. Today's control systems have become faster and more flexible than ever before. Many different types of systems can be blended together to form one integrated whole. Scan rates and refresh times move at speeds that allow changes at an ever-in... View full abstract»

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  • Increasing data historian efficiency

    Publication Year: 2011, Page(s):1 - 14
    Cited by:  Papers (2)
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (212 KB) | HTML iconHTML

    Modern process control systems are continuously increasing the number of process data points monitored in a process control system. These data points, used for process control or energy/environmental management systems, can be brought into a process control system through one of many of possible data interfaces (i.e. 4-20mA, HART, Modbus, OPC, Fieldbus, Profibus, ProfiNet, etc.). The majority of t... View full abstract»

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  • Continuous X-ray diffraction at the buzzi unicem festus plant

    Publication Year: 2011, Page(s):1 - 10
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (804 KB) | HTML iconHTML

    Mineralogy directly indicates quality of material as well as performance of a cement plant. For example cement alite and belite (together with particle size) give an indication of strength development. The gypsum de-hydration states, e.g. hemi-hydrate and anhydrite ratio indicate cement set times. Cement standards are also mineral dependant as some limit additive levels, such as calcite or cementi... View full abstract»

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  • PLC based optimization of finish mills

    Publication Year: 2011, Page(s):1 - 16
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (653 KB) | HTML iconHTML

    This paper examines the evolution of cement finish mill optimization and control logic at Roanoke Cement. The intention is to review lessons learned, and stimulate further discussion and research into finish mill control that will benefit the cement industry. View full abstract»

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  • The use and proper selection of variable speed drives (VSD) for reduced environmental footprint, sustainability and increased plant reliability

    Publication Year: 2011, Page(s):1 - 9
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (521 KB) | HTML iconHTML

    This paper will explore ways that the use of variable speed drives (VSDs) can reduce the energy demand for the average cement plant and coincidentally carbon footprint, a potential future regulatory issue. It will also cover the additional advantages of the drives in each application. Finally the advantages of various technologies of drives and the proper applications of these in a cement plant wi... View full abstract»

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  • Brush lifting system for wound rotor induction motors

    Publication Year: 2011, Page(s):1 - 5
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (1627 KB) | HTML iconHTML

    Wound Rotor Induction Motors have the rotor windings connected to an external resistance through a brush/slip ring assembly. When the brushes are in continuous contact with the slip rings during normal operation of the motor, the brushes and the slip rings experience premature wearing. This leads to frequent stops for maintenance and brush replacements. Once the motor reaches the normal operation ... View full abstract»

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  • Paradigm shift in proper selection criteria of VFD cable for variable frequency drives

    Publication Year: 2011, Page(s):1 - 11
    Cited by:  Papers (1)
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (476 KB) | HTML iconHTML

    Power cable between the inverter and motor is a key component in the drive-motor assembly and is regularly overlooked. This paper describes a new solution for cables used with Insulated Gate Bipolar Transistor (IGBT) Variable Frequency Drives (VFD's). A new cable solution that includes the use of new connector & termination kit that will produce an overall better result and superior performanc... View full abstract»

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  • Pollutant dust suppression

    Publication Year: 2011, Page(s):1 - 9
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (619 KB) | HTML iconHTML

    The cement and mineral processing Industries are currently experiencing immense pressures to greatly reduce and eliminate their pollutants, especially their uncontrolled fugitive dust emissions. Environmental groups and public opinion are consistently championing the need to increase control over industry. Maintaining clean air and water are the driving forces that currently mobilize plant personn... View full abstract»

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  • Alternative method of HG and THC control using existing cement kiln particulate control equipment

    Publication Year: 2011, Page(s):1 - 12
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (701 KB) | HTML iconHTML

    Only three options for control of mercury and organic compounds were available to cement kilns when the latest revisions to the Portland Cement Manufacturing Industry Maximum Achievable Control Technology standards were considered. Since then, Albemarle has developed a technique whereby the existing kiln particulate control device can be used in conjunction with a temperature insensitive, concrete... View full abstract»

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  • Multi-pollutant control for the portland cement industry

    Publication Year: 2011, Page(s):1 - 13
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (209 KB) | HTML iconHTML

    Meeting the compliance limits of the U.S. Environmental Protection Agency's final rule revision to the National Emission Standards for Hazardous Air Pollutants from the Portland Cement Manufacturing Industry (Portland Cement MACT) regulation will be a challenge for cement kilns equipped with only dry particulate control devices (that is, electrostatic precipitator or fabric filter baghouse control... View full abstract»

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  • Organic Rankine Cycle (ORC) based power plant to utilize low-grade waste heat sources

    Publication Year: 2011, Page(s):1 - 10
    Cited by:  Papers (1)
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (503 KB) | HTML iconHTML

    The paper presents an ABB ORC (Organic Rankine Cycle) power plant that is currently under construction at a cement plant in Switzerland. It describes the process engineering solution and the technical advantages of the ORC technology, which uses waste heat from the suspension preheater gas and the clinker cooler waste air, without any need for additional fuel. One unique aspect of the project is t... View full abstract»

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  • Potentials of AFR co-processing

    Publication Year: 2011, Page(s):1 - 8
    Cited by:  Papers (1)
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (697 KB) | HTML iconHTML

    Resources are becoming scarcer and more expensive worldwide driving a search for viable alternatives including the use of Alternative Fuels and Raw Materials (AFR). The cement industry began to use Residue Derived Fuels (RDF) after the oil crisis in the early 1980s. By 2010, their use had increased to about 10% replacement of the total thermal energy demand. Utilizing mainly used oil and tyres, RD... View full abstract»

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  • The Gas Suspension Absorber at Norcem's Brevik plant

    Publication Year: 2011, Page(s):1 - 6
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (910 KB) | HTML iconHTML

    In the cement industry many plants are looking for ways to reduce their gaseous emissions to comply with new environmental laws. Such is the case with the Norcem plant in Brevik, Norway, which committed to reduce emissions of sulfur dioxide (SO<sub>2</sub>) by 400 tons per year. This is part of the Gothenburg Protocol, an objective to reduce overall industrial sulfur emissions in Norwa... View full abstract»

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  • Calciner design for lower CO and NOx using MI-CFD analysis to optimize “Hot-Reburn” Conditions

    Publication Year: 2011, Page(s):1 - 18
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (1709 KB) | HTML iconHTML

    In an effort to reduce production costs, the cement industry is using more and more alternative fuels and raw materials (AFRs) than ever before. Some successful examples show thermal substitution rate (TSR) as high as 90%. Generally, a higher than 20-30 TSR requires detailed analysis of not only combustion aspects of AFRs, but also their impact on emissions, kiln stability and clinker quality. Usu... View full abstract»

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  • Gaining visibility and control of raw materials at lafarge cave-in-rock cement quarry

    Publication Year: 2011, Page(s):1 - 9
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (419 KB) | HTML iconHTML

    The cement production facility at Lafarge, Joppa, Illinois produces world-class oil well cement as well as top-quality Type I/II cement and various blended cements. The cement is made from limestone, fly and bottom ash, silica, alumina and iron using crushed rock moved via barge from the quarry located 74 miles upriver. When the crushed rock arrives at the cement plant it is ground in two raw grin... View full abstract»

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  • Clinker kiln optimization: Pushing your equipment to the limit

    Publication Year: 2011, Page(s):1 - 11
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (400 KB) | HTML iconHTML

    A methodology for clinker kiln optimization in cement plants is presented in this paper. Mass and energy balances are described as the fundamental optimization tool for the cement industry. Several case studies for specific applications of the proposed methodology are shown. View full abstract»

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  • Preheater upgrades

    Publication Year: 2011, Page(s):1 - 7
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (456 KB) | HTML iconHTML

    The paper introduces the possibility that many older plants facing the demands of modern industry can be upgraded with attractive technical and financial projects. The step-by-step process always needs a case by-case approach and starts with ensuring that current operation is optimal. A string of usual issues can be checked and improved before serious feasibility studies are made. Thereafter the r... View full abstract»

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  • Cylindrical powder cement cooler automation

    Publication Year: 2011, Page(s):1 - 5
    Cited by:  Papers (2)
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (334 KB) | HTML iconHTML

    Quality control standards of cement manufacturing and ready-mix operations require finished cement temperatures to meet a maximum upper limit. One way of meeting this requirement is the use of cylindrical powdered cement coolers. These cement coolers require water to flow down the outside of the cylindrical shell counter to the flow of the cement inside the shell. The water flow is normally contro... View full abstract»

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  • Blending and control systems technologies for cement raw materials revisited - PGNA analyzer application review - An example from Lafarge's Davenport plant in Buffalo, Iowa Usa

    Publication Year: 2011, Page(s):1 - 18
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (2237 KB) | HTML iconHTML

    During the past 10 years, the cement-industry application of PGNA on-line analysis in the raw-mix logic of both new plants and as a retrofit has grown from a recent innovation to an industry standard practice. The variety of applications has grown and presents a challenge to designers to choose the optimum raw-mix logic. This paper briefly reviews the applications of analyzers and highlights some ... View full abstract»

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  • Central cone silos for cement

    Publication Year: 2011, Page(s):1 - 8
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (1580 KB) | HTML iconHTML

    Cement silos are either part of the production process in integrated cement plants or they can also be the key part of distribution terminals. For the cement industry these storage silos are very important because this allows a continuous production while the cement dispatch can be discontinuous. Largest cement storage silos in the cement industry are built with diameters up to 30 m while typical ... View full abstract»

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  • Innovations in storage silo floor design and operation

    Publication Year: 2011, Page(s):1 - 7
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (178 KB) | HTML iconHTML

    Everything we see and read about today somehow relates to saving the environment. The new “buzz” phrase we hear is “Go Green” when developing new projects. The goal is to design systems to operate at reduced energy levels and reduced filtration requirements while simultaneously improving their performance. In 2005, Lafarge Canada Inc. installed two storage silos with innovative fluidized floor des... View full abstract»

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  • Alternative fuels: Challenges in receiving, preparation, storage and blending

    Publication Year: 2011, Page(s):1 - 5
    Request permission for commercial reuse | Click to expandAbstract | PDF file iconPDF (162 KB) | HTML iconHTML

    Starting with the receiving of material, the paper will show the various segments for processing, storage and on-site transport which are required in any project for the use of solid alternative fuels. The importance of being able to blend different fuel types/qualities will be emphasized. The cement plant can improve the consistency of alternative fuels by blending the different fuel qualities in... View full abstract»

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