2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)最新文献

{"title":"Blending/Homogenizing Silos – All They’re Cracked up to Be?","authors":"G. Lynskey","doi":"10.1109/CITCON.2019.8729102","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729102","url":null,"abstract":"Consistency in raw material is vital for the production of cement with reliable characteristics. As the process of cement production has developed, so has the preparation and storage of the blend of materials used to produce clinker. This paper will discuss some of the history of how raw material has been produced, stored, and transported to the kiln. The effects of the changes on the storage of the material, more recently in storage silos, will be a major focus of the paper.From vertical kilns to horizontal, then the wet process to the dry process, to current day multi stage preheater towers, with silos of varying arrangements where material is aerated by twelfths, quarters, flat bottoms or inverted cones that use less power and air, the sophistication of the process has, in some cases, left the structural engineer responsible for the design of the storage of the raw material in the dark, sometimes with disastrous effects.Based on past experience and observations of dozens of existing homogenizing and blending silos, the structural engineering performed for the design of the silo storing the raw material prior to being taken to the preheater has been largely insufficient. Why? Has the structural engineer taking this responsibility not understood the principles of the process in the silo? Or is it a simple communication problem, where the process engineer has not communicated what is really happening inside the silo when the material is blended / homogenized. The answer is likely \"both\".It should be stated explicitly that the homogenizing / blending silos of recent years differ from most storage spaces. In most cases, material placed in a silo is in a static condition: material is placed inside, and stored until it is ready to be reclaimed. While that is a gross overstatement, compare this with the demands on a blending / homogenizing silo. These structures are not just expected to hold material, but they instead are now part of the process. Material is placed inside them and manipulated while in the storage space, with the desire to make them more homogenous.This blending / homogenizing process fluidizes or moves the material in segments. This causes the material in the silo to take on different properties in these different segments. Depending on the process being implemented (i.e. homogenization / blending, number of segments used, inverted cones, flat bottoms, eccentric or concentric discharge, etc.), the fluidized / activated material in the silo will be less stiff and exert less pressure outward than the remaining static material. This difference in stiffness and pressure results in bending in the silo walls, causing stresses that nearly always exceed those originally expected for uniform material pressure. This bending causes the overstress of the silo walls. This overstress first manifests itself in vertical cracking, then delaminated and spalled concrete, and in worst cases, catastrophic failure.Why are there so many homogenizing / blend","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130909271","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":"Ceramic Thermal Barrier Coating Technology An Evolution in Corrosion Prevention & Asset Protection","authors":"Steve O. Williams","doi":"10.1109/CITCON.2019.8729104","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729104","url":null,"abstract":"Plant asset preservation and reduced maintenance is critical to any plant’s bottom line. Corrosion is the unpredictable adversary that afflicts plants, usually at the worst time and with costly impact. There are many reasons why this cancer spreads and attacks APC (Air Pollution Control) and Process equipment. However, two major causes in cement, lime, mineral and other industrial facilities are Acid Dew Point and High Temperature Corrosion (Oxidation).","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"56 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128712259","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":"Medium Voltage Adjustable Speed Drives: Power Factor and Motor Control – A Beautiful Combination","authors":"Manish Verma, D. Phares, B. Dick","doi":"10.1109/CITCON.2019.8729100","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729100","url":null,"abstract":"There has been a significant evolution in power semiconductor devices from small, low power devices to very high capacity devices. As a result, multi-megawatt range adjustable speed drive (ASD) systems are increasingly being used not only in the global cement industry but others such as oil & gas, mining, water/wastewater, and power generation. In a modern cement plant, Medium Voltage (MV) ASDs are used on ID fans, kilns, separators, finish mill, ball/sag mills, conveyors, & pumps. A new generation of regenerative medium voltage adjustable speed drives are being applied that not only deliver motor control but also can inject reactive power back to the connected bus. This topology of drives helps in improving power factor and providing voltage support thereby reducing or eliminating nuisance trips due to power instability, optimize the size of backup generators, release capacity tied up in lagging loads thereby enabling plant expansion. The focus of the paper is to show how this novel topology of drives works, application considerations, procurement guidance, and correct sizing of the ASD to meet overall VAR compensation objectives of a facility. Finally, a case study is presented where the end user applied an ASD for VAR compensation and discuss the results.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"35 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122455997","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":"Ground Fault Protection Applications in Low Voltage Motor Control Systems for Process Industries","authors":"M. Hussey, S. Drzymala","doi":"10.1109/CITCON.2019.8729111","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729111","url":null,"abstract":"Continuous processes require motor control systems to maintain uptime in a variety of installed system types. New capabilities in low-voltage (LV) motor protective relays have enabled ground fault protection to be specially tuned for these process needs. This paper will examine several design alternatives for engineers considering site ground fault protection needs in low voltage motor control systems for commonly applied power system types including ungrounded, solidly grounded and resistance grounded). The importance of application in motor life, fault detection, motor failure examples due to ground fault and electrical safety will be considered. Typical methods of ground fault protection in LV motor control centers and common challenges for ground protection schemes including residual, zero sequence and high resistance ground (HRG) pulse detection systems to achieve fast fault detection and ground fault protection for LV motor control centers (MCCs) will be addressed. Finally, a case study involving an industrial project technology review and installation of a HRG pulse detection system for a newly installed LV MCC will be reviewed.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"38 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126079860","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":"What’s Up with Vertical Mill Drives?","authors":"J. Kline","doi":"10.1109/CITCON.2019.8729092","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729092","url":null,"abstract":"Drive systems for large vertical mills have proven to be a reliability issue for many cement producers. As mill sizes have increased over time the size of the motors and corresponding gear boxes have increased as well. The lack of reliability of these large and expensive drive sets has led to two outcomes; equipment suppliers have worked diligently to improve drive system design to provide a more robust drive. At the same time equipment owners have taken up different strategies to minimize potential losses from drive system failures.This paper will explore the evolution of vertical mill drive system designs. It will also focus on some of the strategies used by cement producers to offset potential losses from large vertical mill drive system failures. It will also explore techniques to monitor and preserve the operation of these drive systems.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"55 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114677742","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 Cement Mill Upgrade Story Reboot","authors":"A. Simmons, Gurjeet Sarao, D. Campain","doi":"10.1109/CITCON.2019.8729112","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729112","url":null,"abstract":"Vertical roller mills (VRM) for cement grinding have now been in operation in North America for almost 20 years. Many opportunities exist to upgrade the older vertical mills with the latest technologies to improve efficiency. Recently a southern California cement plant upgraded their vertical cement mill circuit, one of the first installed in the US, with an integrated solution including a latest generation separator and advanced process control software. The project objective was to improve mill stability and reduce energy consumption for the complete circuit.This paper, jointly presented by the producer and supplier, will discuss the project justification, the scope of the upgrade package from the supplier, and results achieved from both the mechanical and digital components.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"97 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122537005","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":"Lessons Learned from Installing an «At Line» Free Lime Analyzer to Control and Optimize the Cement Kiln Operation","authors":"J. M. Ontiveros, A. Haider","doi":"10.1109/CITCON.2019.8729095","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729095","url":null,"abstract":"Traditional instrumentation and control at a cement manufacturing plant is carried out by taking samples from different processing points and analyzing them in a central laboratory, either manually, or in some cases automatically. For clinker, the samples are typically taken after the cooler on the pan conveyor and analyzed every 2 hours. With this method the clinker free lime result, is not truly representative, is too late and too infrequent to be used to correctly control the kiln burning zone conditions.In 2015, the plant management decided to install ‘At-line fully automatic Free Lime Measurement system’ taking the clinker sample directly at the kiln discharge before the cooler. This solution presents a number of advantages over the traditional methods – notably in terms of more timely controls and of higher frequency, resulting in fuel and power savings and better and more stable product quality. The system was successfully commissioned at the end of 2016This paper will provide a brief description of the control instrument as it was implemented at the cement plant in Arizona, its installation, the teething problems that were faced and resolved, its effectiveness in helping the kiln operators control the process, the substantial improvement in clinker consistency as seen over the last 2 years, as well as the very significant and consistent savings that were achieved and that quickly paid back for the investment.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"6 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131325139","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":"Getting the Most from Expert Control Systems","authors":"J. Kline","doi":"10.1109/CITCON.2019.8729109","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729109","url":null,"abstract":"Computer processing power has grown exponentially over the past decades. At the same time the sophistication of sensors has increased, providing more numerous and accurate data points for control. Based on these trends it would seem that expert systems would be more capable and more in demand than ever. However, many plants and companies have struggled to maximize the benefits of expert control systems.Expert control has been shown to provide increased operational efficiency with lower emission levels and reduced costs. However, these targets can be elusive if the expert system is not properly understood and the prerequisites for success not followed. This paper explores some of the issues that inhibit expert control system operation. The paper provides some guidelines for optimizing existing expert control systems and provides prerequisites for companies considering the installation of expert control systems.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121294423","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":"Drive-thru Terminal Loadout Silos","authors":"B. Bateman, Tom Beck","doi":"10.1109/CITCON.2019.8729093","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729093","url":null,"abstract":"With the potential increase of cement consumption in North America, cement companies continue to look for ways to deliver the product to consumers in an economical efficient way that is also environmentally friendly. As a result, geographically localized storage and transport systems are needed to facilitate the distribution of cement from the plant or import terminal to the point of use. This paper focuses on the drive-thru terminal loadout silos that are used to receive and store cement that is then loaded into truck or rail for consumption in the local market, and the varying aspects of each type of storage system.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"39 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124366664","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 Hybrid Technology for Fast Laser Gas Analysis in High Dust Processes","authors":"K. B. Floor","doi":"10.1109/CITCON.2019.8729098","DOIUrl":"https://doi.org/10.1109/CITCON.2019.8729098","url":null,"abstract":"A gas analysis system for high dust applications was successfully tested at a cement plant at the exit of a dedusting cyclone. The response time was 5 s in a process gas stream with up to 200 g/m3 of dust. The test employed a new hybrid gas analysis solution that combines in situ and extractive gas analysis technologies. The test confirmed that a hybrid gas analysis system can provide a reliable and rapid measurement response which is critical in process streams with potentially explosive or toxic gases. The rapid response provides improved operational safety and can enable less conservative process interlock levels. This can reduce the process upsets caused by interlock trips, particularly where gases such as CO, CH4, and NH3 are involved. It will also provide operators with a larger operational window for combustible management which is especially beneficial with Refuse-Derived Fuels (RDF) and tighter process control in Selective Non-Catalytic Reduction (SNCR) dosing operations.","PeriodicalId":135175,"journal":{"name":"2019 IEEE-IAS/PCA Cement Industry Conference (IAS/PCA)","volume":"97 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122101526","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}