{"title":"Benchmarking to improve all aspects of cement plant performance","authors":"M. Clark","doi":"10.1109/CITCON.2003.1204719","DOIUrl":"https://doi.org/10.1109/CITCON.2003.1204719","url":null,"abstract":"Benchmarking is a well-established tool for performance comparison and a necessary first step in any performance improvement process. It measures current performance against appropriate peers, and the gap between current performance and best practice. This allows reasonable objectives and targets to be set and plans to be drafted to achieve those objectives and targets. However, benchmarking can be conducted at a number of levels, in a number of ways, and consider multiple aspects of the management and operation of a cement business. Different audiences within a cement company want different levels of management information from performance benchmarking. This paper illustrates some of the possibilities with reference to examples.","PeriodicalId":115477,"journal":{"name":"Cement Industry Technical Conference, 2003. Conference Record. IEEE-IAS/PCA 2003","volume":"35 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2003-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130186794","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":"New power distribution system at Signal Mountain Cement","authors":"J. Schaadt","doi":"10.1109/CITCON.2003.1204713","DOIUrl":"https://doi.org/10.1109/CITCON.2003.1204713","url":null,"abstract":"Cement plant process modifications require varying degrees of modifications to the plant power distribution system. These modifications come with their own set of challenges, problems, and opportunities. This paper serves as a case study based on what was done at the new Signal Mountain Cement plant in Chattanooga, Tennessee, where an outdated wet process plant was essentially replaced with state of the art process technology. This paper is divided into the following sections: history and overview of Signal Mountain Cement Company; overview of the old power distribution system; and overview of the new power distribution system.","PeriodicalId":115477,"journal":{"name":"Cement Industry Technical Conference, 2003. Conference Record. IEEE-IAS/PCA 2003","volume":"9 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2003-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123988717","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":"Behavior and measurement of mercury in cement kilns","authors":"C. Senior, A. Sarofim, E. Eddings","doi":"10.1109/CITCON.2003.1204725","DOIUrl":"https://doi.org/10.1109/CITCON.2003.1204725","url":null,"abstract":"Mercury is one of a number of pollutants (like dioxins) that persist in the environment and bioaccumulate in the food chain. Because of its toxicity and the potential for bioaccumulation, mercury emissions to the environment are the subject of environmental regulation. US EPA estimates that 87% of the man-made emissions of mercury come from point sources of combustion. There are currently emission limits on mercury from certain categories of combustion sources, including cement kilns and incinerators burning hazardous waste. Cement kilns that do not burn hazardous waste are not subject to these emission standards. However, EPA is currently reviewing the need for emission standards for mercury and other pollutants from cement kilns. In this paper, we review the chemistry of mercury in the cement-making process, methods for measuring mercury in combustion systems and the experience in other industries with controlling mercury emissions from combustion sources. Emphasis is placed on the chemical forms of mercury in the process.","PeriodicalId":115477,"journal":{"name":"Cement Industry Technical Conference, 2003. Conference Record. IEEE-IAS/PCA 2003","volume":"57 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2003-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130132837","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":"An innovative solution for waste utilization","authors":"B. Keefe, R. Shenk","doi":"10.1109/CITCON.2003.1204721","DOIUrl":"https://doi.org/10.1109/CITCON.2003.1204721","url":null,"abstract":"For preheater kiln systems, experience has shown that it is possible to substitute upwards of 25% of the fuel with waste material in \"lump\" form such as whole car tires. However, most kiln systems supplied today are of the precalciner type where typically only 40% of the fuel is fired in the rotary kiln, with the balance fired to the calciner. This means that lump waste fuels may typically substitute only 10% of the total fuel requirement of the kiln system. This paper presents an innovative technology that facilitates the burning of waste-derived fuels, especially large-sized alternative fuels, that otherwise cannot be economically ground or shredded to the fineness needed to 'burn in suspension' as required by modern precalciner kiln systems. The device is a large, rotating furnace hereto referred to as a \"disc\" that is simplistically capable of controlling two primary requirements for complete combustion: retention time and temperature. The disc, continuously satisfies these two requirements making it possible to burn alternative fuels (e.g. whole automobile tires) in the calciner that, otherwise, would not be possible due to their poor gas-suspension and/or poor burnout characteristics. The disc is an extremely simple combustion device which may be installed as part of any new calciner, as well as many existing calciners. As a result of this invention, upwards of 60% or more of the calciner's fuel requirement may be substituted with waste-derived fuels in lump form.","PeriodicalId":115477,"journal":{"name":"Cement Industry Technical Conference, 2003. Conference Record. IEEE-IAS/PCA 2003","volume":"49 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2003-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131009345","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":"\"Changing process priorities when firing alternate fuels\"","authors":"E. R. Hansen","doi":"10.1109/CITCON.2003.1204723","DOIUrl":"https://doi.org/10.1109/CITCON.2003.1204723","url":null,"abstract":"A presentation is given on process modifications to accommodate alternate fuels and firing methods. Discussion is made on process control strategy that makes combustion control the priority, burner modification to boost flame temperature, and the addition of energy for mixing of the combustion gasses to minimize excess air requirements. The implementation of these process modifications considers clinker quality, emissions and high alternate fuel substitution. Results from several facilities are included.","PeriodicalId":115477,"journal":{"name":"Cement Industry Technical Conference, 2003. Conference Record. IEEE-IAS/PCA 2003","volume":"30 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2003-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124578285","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":"Remote monitoring and diagnostics of large rotating machinery","authors":"D. F. Hofmann, D. Phares","doi":"10.1109/CITCON.2003.1204708","DOIUrl":"https://doi.org/10.1109/CITCON.2003.1204708","url":null,"abstract":"Large motors constitute a major expense from a capital, operational, and maintenance perspective in today's cement plant. A history and overview of signals and measurements in large motor applications is given. As a means of optimizing their performance, systems are being developed in the industry to monitor and diagnose large motor \"health\". This is a shift from the strategies of the past, which put the primary emphasis on conventional maintenance procedures. The migration will be to monitor and diagnose motor health while the motors remain in operation, providing a means to help optimize plant efficiency, productivity, and maintenance costs.","PeriodicalId":115477,"journal":{"name":"Cement Industry Technical Conference, 2003. Conference Record. IEEE-IAS/PCA 2003","volume":"48 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2003-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133540918","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":"Total power management for the cement industry","authors":"M. W. Leinmiller","doi":"10.1109/CITCON.2003.1204711","DOIUrl":"https://doi.org/10.1109/CITCON.2003.1204711","url":null,"abstract":"Power. Lots of power. Where does it all go? How much is it really costing the plant? Are there more effective ways of operating cement plants'? Cement manufacturing facilities run the gamut from aging relics (at the far reaches of even more ancient power systems) to the most sophisticated, high-tech process plants you'll find anywhere. What all of these plants share is a seemingly insatiable appetite for power. The goal of this paper is to give some practical steps for how to go about implementing a simple yet effective continuous power monitoring solution. The value of continuous power monitoring comes in many forms, the greatest value of which is realized by those who take a proactive approach to maintaining their facility and maximizing its value.","PeriodicalId":115477,"journal":{"name":"Cement Industry Technical Conference, 2003. Conference Record. IEEE-IAS/PCA 2003","volume":"30 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2003-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124099506","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":"Clinker cooler hydraulic drives","authors":"A. Chavarro, K. Patel, J. Knabbe, R. Worthington","doi":"10.1109/CITCON.2003.1204709","DOIUrl":"https://doi.org/10.1109/CITCON.2003.1204709","url":null,"abstract":"For many years modifications to grate cooler technology have continuously developed. Many of the grate coolers supplied for the cement industry over the last 50 years include hydraulic drives. Continuous developments for the clinker cooler hydraulic drive have achieved a considerable improvement of operation, reliability and capacity. The following two plant modifications are good examples of the continued development of the hydraulic drive meeting the expectations of cement plant operators. The Cemento Votorantim S.A. Fabrica Santa Helena, Brazil decided in January 2001 to make a modification to their grate cooler drive on the 2nd grate. The plant replaced the existing mechanical drive with hydraulic drive including a grate motion control, compact swing supports and a moving frame guide. The Lafarge Cementos Maua, Matozinohos plant, Brazil also decided to make an improvement on their 2nd grate cooler drive to eliminate continuous kiln shutdowns due to grate mechanical problems and improve performance. The plant replaced the existing mechanical drive with a hydraulic drive including a local control box and compact swing supports in June 2000. Comparison is made for various parameters before and after modifications for: power consumption; air volume; clinker temperature; reliability; and grate control. Special discussion for different arrangements of grates in conjunction with hydraulic cylinders complete this paper.","PeriodicalId":115477,"journal":{"name":"Cement Industry Technical Conference, 2003. Conference Record. IEEE-IAS/PCA 2003","volume":"35 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2003-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127729602","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}
R. Gebert, C. Rinschler, C. Polizzi, U. Harig, G. Pranghofer, S. J. Miller
{"title":"A new filter system, combining a fabric filter and electrostatic precipitator for effective pollution control behind cement kilns","authors":"R. Gebert, C. Rinschler, C. Polizzi, U. Harig, G. Pranghofer, S. J. Miller","doi":"10.1109/CITCON.2003.1204729","DOIUrl":"https://doi.org/10.1109/CITCON.2003.1204729","url":null,"abstract":"A filter system for particulate control has been developed as an air pollution control device that closely integrates electrostatic precipitation (ESP) and fabric filter technologies into a compact, durable, cost-effective device that produces superior filtration results. Its unique configuration promotes a synergy between these two technologies whereby the filter bags are able to operate at high air-to-cloth (A/C) ratios and be cleaned without the typical concern with dust re-entrainment. The filter requires fewer components than other comparable air pollution control technologies, allowing the use of higher performance and very durable components. Components such as filter bags made with a highly efficient expanded polytetrafluoroethylene (ePTFE) membrane, rigid ESP discharge electrodes, and pulse jet cleaning systems form an integral part of the overall performance which results in superior particulate control at costs comparable to currently used technologies. This filter technology is easily adapted to new installations as well as retrofits of existing ESPs. This paper presents details about the design and operation of the filter along with performance data from an operational cement kiln application in Italy and its associated benefits in this market.","PeriodicalId":115477,"journal":{"name":"Cement Industry Technical Conference, 2003. Conference Record. IEEE-IAS/PCA 2003","volume":"33 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2003-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124799996","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":"New Source Review reform as applied to the Portland cement industry","authors":"W. L. Greer, A. Heinerikson","doi":"10.1109/CITCON.2003.1204727","DOIUrl":"https://doi.org/10.1109/CITCON.2003.1204727","url":null,"abstract":"Often, in the haste of making desirable improvements to a cement plant operation, insufficient thought is given to the regulatory requirements of New Source Review (NSR). The enforcement ramifications of a failure to fully consider NSR can be time-consuming and expensive. It is important that decision-makers recognize the need to consider NSR requirements during planning for projects. On December 31, 2002, the United States Environmental Protection Agency (USEPA) promulgated important final changes to NSR procedures for existing plants to simplify the NSR process and to provide more certainty and flexibility to the regulated community. The USEPA also proposed a system to clarify the requirements for certain activities to qualify for the exclusion of routine maintenance, repair and replacement (RMRR) from NSR. This paper presents a brief review of significant points in NSR and discusses, in general terms, the final and proposed changes to the NSR program.","PeriodicalId":115477,"journal":{"name":"Cement Industry Technical Conference, 2003. Conference Record. IEEE-IAS/PCA 2003","volume":"23 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2003-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116742154","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}