{"title":"Cogeneration systems in material drying applications","authors":"D. Walker","doi":"10.1109/CITCON.2002.1006488","DOIUrl":"https://doi.org/10.1109/CITCON.2002.1006488","url":null,"abstract":"The potential exists to offset fuel purchases associated with material drying, as well as electric energy purchases, with the installation of a combustion turbine generator for cogeneration at cement plants, and other plants where material drying in kilns or furnaces is performed. Cogeneration, also referred to as combined heat and power, is the simultaneous generation of two forms of useful energy from one energy/fuel source. A cogeneration concept has been considered due to the coincident electric power and thermal loads present at cement manufacturing operations. For this application, a natural gas fuel source would be used to generate both electric energy and heat in the form of turbine exhaust gases. The purpose of this document is to advise cement manufacturing facilities of the potential of cogeneration, and present a concept of how cogeneration could be implemented. This document also defines the pertinent economic drivers and determine how project feasibility is affected. Major cogeneration plant equipment and systems are described. Feasibility for a test case, which considers installation of a nominal 13 MW gas turbine, is presented.","PeriodicalId":103359,"journal":{"name":"IEEE-IAS/PCS 2002 Cement Industry Technical Conference. Conference Record (Cat. No.02CH37282)","volume":"26 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2002-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"117094639","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}
{"title":"Cement mill system upgrade","authors":"D. Longhurst","doi":"10.1109/CITCON.2002.1006506","DOIUrl":"https://doi.org/10.1109/CITCON.2002.1006506","url":null,"abstract":"The following case study examines a range of existing techniques available which have been applied over the past 15 years at the Arizona Portland Cement plant on three different grinding systems. Four modifications to these existing systems were completed during this time, and two more modifications are planned. Planning for future needs has allowed the maximized use of existing equipment, while increasing both the quality and quantity of finished product to meet the requirements of today and tomorrow. With possible modifications planned in the future, the finish grinding capacity of these three systems will have been increased from approximately 74 mtph to 300 mtph through additions to, and the upgrading of, existing equipment. While the capacity increased by 300%, the specific power requirement decreased by 20%. This value is for the major pieces of equipment only, based-mainly on full use of installed power.","PeriodicalId":103359,"journal":{"name":"IEEE-IAS/PCS 2002 Cement Industry Technical Conference. Conference Record (Cat. No.02CH37282)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2002-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128166413","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}
{"title":"Energy efficiency improvement in the cement industry","authors":"B. Segal","doi":"10.1109/CITCON.2002.1006493","DOIUrl":"https://doi.org/10.1109/CITCON.2002.1006493","url":null,"abstract":"There are numerous opportunities to improve energy efficiency and reducing the effects of harmonic distortion in cement manufacturing power distribution systems. The first step is to choose the most energy efficient equipment, not necessarily choosing the most inexpensive machinery. The second step is to apply modern technologies to the power distribution systems for the equipment. Active harmonic filters and power factor correction conditioners automatically follow changing load conditions, resulting in energy cost reduction. Studies at the Power Electronics Application center in Knoxville, TN, have shown that harmonics and low power factor do create voltage and power losses in cables, contactors, and transformers reducing system capacity and waste energy. Power system modeling, awareness of which technologies to use is necessary to reduce energy costs. Analysis tools are being developed to assist design engineers to optimize system efficiency.","PeriodicalId":103359,"journal":{"name":"IEEE-IAS/PCS 2002 Cement Industry Technical Conference. Conference Record (Cat. No.02CH37282)","volume":"10 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2002-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"120937541","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}
{"title":"A real world innovative concept for plant information integration","authors":"U. Herzog, R. Hantikainen, M. Buysse","doi":"10.1109/CITCON.2002.1006526","DOIUrl":"https://doi.org/10.1109/CITCON.2002.1006526","url":null,"abstract":"The drive for continuous improvement is probably one of the main constants in the cement industry. So it is the case for information systems. On both the business administration and the production information systems, there is a strong push for tighter integration in order to cut down on overlaps, multiple instances of similar data, expensive maintenance and so on. Excitement alone for (isolated) point solutions is just not enough. The value of a point solution nowadays is only appreciated, if it fits the larger picture of the total enterprise IT strategy. In the real world, it is not economically viable to replace all systems at the same time to the latest and same technology platforms. Technically this means that the focus shifts to ensuring consistency of information throughout a heterogeneous landscape of production information systems and business systems. In production management, production accounting is a tedious manual activity in reporting balanced production figures. There are imperfections such as sensor errors, limited measurement accuracy, calibration drift, transient accumulation, roundup, spillage and incomplete calculation. Production figures inevitably require reconciliation and balancing before finalizing month-end closing. This paper also shares the experiences and benefits of a large cement producer in the implementation of modern, integrated solutions across multiple plants.","PeriodicalId":103359,"journal":{"name":"IEEE-IAS/PCS 2002 Cement Industry Technical Conference. Conference Record (Cat. No.02CH37282)","volume":"7 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2002-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128536547","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}
{"title":"Staged combustion for NO/sub x/ reduction using high pressure air injection","authors":"E. Hansen","doi":"10.1109/CITCON.2002.1006514","DOIUrl":"https://doi.org/10.1109/CITCON.2002.1006514","url":null,"abstract":"The effects on emissions by applying high-pressure air injection on rotary kilns to achieve effective mixing and staged combustion are presented. A technique of using the energy of high-pressure air jets to achieve cross-sectional mixing in a tertiary combustion zone in rotary kilns resulting in reduced excess air requirement for optimum combustion is described. An additional result of the mixing method is the creation of a sub-stoichiometric secondary combustion zone that reduces the emission of nitrogen oxides.","PeriodicalId":103359,"journal":{"name":"IEEE-IAS/PCS 2002 Cement Industry Technical Conference. Conference Record (Cat. No.02CH37282)","volume":"23 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2002-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"117137102","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}
{"title":"Higher efficiency-what is the real cost?","authors":"J. J. Stroker","doi":"10.1109/CITCON.2002.1006489","DOIUrl":"https://doi.org/10.1109/CITCON.2002.1006489","url":null,"abstract":"With the problems that California had with electrical energy in 2001, it has only emphasized the need to look at the true cost of high efficiency energy devices used by cement plants since electrical energy is among the top expenses in producing cement. This paper focuses on low voltage induction motors and lighting systems. The low voltage induction motors generally account for about 30% of the electrical energy consumed by a cement plant. The lighting systems generally account for about 3-5% of the electrical energy consumed by a cement plant but it is a fixed load that does not directly contribute to production. Life cycle cost analysis is used to determine the true costs of this equipment.","PeriodicalId":103359,"journal":{"name":"IEEE-IAS/PCS 2002 Cement Industry Technical Conference. Conference Record (Cat. No.02CH37282)","volume":"9 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2002-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115032226","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}
{"title":"Dealing with motor winding problems caused by inverter drives","authors":"M. Fenger, S. Campbell, J. Pedersen","doi":"10.1109/CITCON.2002.1006495","DOIUrl":"https://doi.org/10.1109/CITCON.2002.1006495","url":null,"abstract":"Random wound stator windings operating in utility and industrial plants have failed when exposed to the fast rise-time voltage surges coming from inverters. Studies show that the failure is due to a combination of bad luck in specific motor installations (resonance phenomena caused by power cable length and surge impedance ratios) together with the fact that modern inverter-fed drives (IFDs) create tens of thousands of surges per second with rise-times as fast as 50 ns. Measurements on motors show that these surges create partial discharges (also called corona) and these discharges may eventually destroy the turn-to-turn and/or phase-to-phase insulation, resulting in premature motor failure. The paper discusses the specific mechanisms involved in the stator winding failure due to IFDs and present the measurements and analysis from surge monitoring installed on many different motors. Although some motors may experience short rise-time, high magnitudes surges, most motors experience either low magnitude and/or long rise-time surges, which are relatively harmless. Usually, several different magnitudes and rise-times are present from the same IFD. Thus, it seems that conventional motor stators can be safely used in many (but not all) IFD applications. Methods are presented to determine when special IFD duty motors are needed. Voltage surge tests, as well as partial discharge tests, can help the user insure that motors can successfully operate in severe applications.","PeriodicalId":103359,"journal":{"name":"IEEE-IAS/PCS 2002 Cement Industry Technical Conference. Conference Record (Cat. No.02CH37282)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2002-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128991051","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}
{"title":"Plant automation at Signal Mountain Cement","authors":"M. Maranzana","doi":"10.1109/CITCON.2002.1006515","DOIUrl":"https://doi.org/10.1109/CITCON.2002.1006515","url":null,"abstract":"The advent of new technologies that has taken place in recent years in the control and information systems in modern cement plants has allowed drastic improvements in the efficiency and reliability of the equipment and in the quality of the product. Information and data are much more readily available to many more people in different locations and in real time, improving and expediting the decision-making processes. This paper outlines the main characteristics and principles of the control system of the new Signal Mountain Cement plant, hoping to give those involved with control and information systems some hints and ideas to apply to their projects.","PeriodicalId":103359,"journal":{"name":"IEEE-IAS/PCS 2002 Cement Industry Technical Conference. Conference Record (Cat. No.02CH37282)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2002-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129171626","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}
{"title":"Finish grinding with vertical roller mills-operating data","authors":"C. Oesch, B. Jurko","doi":"10.1109/CITCON.2002.1006505","DOIUrl":"https://doi.org/10.1109/CITCON.2002.1006505","url":null,"abstract":"Vertical roller mills offer significant potential for savings when used for finish grinding. Two installations in Peru and the Dominican Republic are being examined with specific data on cement production, product fineness, specific power consumption and concrete strength. The vertical mill at Cementos Pacasmayo, SA in Peru was commissioned in December 1999, and the mill at Cementos Nacionales in Dominican Republic was commissioned in August 2000. Installed production rates range from 40 stph to over 200 stph per mill. The variety of sizes makes the vertical roller mill an attractive alternative to ball mills for additional cement grinding capacity or as stand alone installations for modern cement producers.","PeriodicalId":103359,"journal":{"name":"IEEE-IAS/PCS 2002 Cement Industry Technical Conference. Conference Record (Cat. No.02CH37282)","volume":"34 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2002-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131647932","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}
{"title":"The Kosmosdale expansion project [cement plant upgrade]","authors":"A. Rowley, D. Babel","doi":"10.1109/CITCON.2002.1006502","DOIUrl":"https://doi.org/10.1109/CITCON.2002.1006502","url":null,"abstract":"Kosmos Cement Company, a partnership between Southdown (now CEMEX, responsible for operation) and Lonestar Industries (now Heidelberger) decided in 1998 to increase the clinker production of the Kosmosdale plant from 2500 stpd to 4700 stpd. To achieve this capacity increase of almost 90%, extensive additions and modifications had to be made in almost all manufacturing areas. These main areas were the quarry stockpile stacker and river load out conveying, a new higher capacity rock barge fleet, upgrades to the limestone unloading conveying system, limestone storage, raw meal transport, kiln feed system, pyro-process system, coal grinding, clinker handling, finish grinding system, cement storage and barge loading system, an addition to the main electrical substation and a new plant wide control PLC/HMI automation system. The paper describes the many challenges to execute this unique project in tight and restricted areas while at the same time maintain ongoing plant operation. Only a three month general plant shut down was scheduled for demolition and replacement of the existing gyro-process equipment and tie-ins of the various areas into the existing systems. Due to the time constraints this paper concentrates mainly on the pyro-process area.","PeriodicalId":103359,"journal":{"name":"IEEE-IAS/PCS 2002 Cement Industry Technical Conference. Conference Record (Cat. No.02CH37282)","volume":"171 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2002-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133278547","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}