{"title":"A DCS/PLC cross-platform system at Lafarge Corporation-Joppa plant","authors":"R. Jones, J. Chan","doi":"10.1109/CITCON.1996.507140","DOIUrl":"https://doi.org/10.1109/CITCON.1996.507140","url":null,"abstract":"Lafarge Corporation has installed several brands of distributed control systems (DCS) and PLC systems in our North American plants. In the past, the system selection criteria focused on state-of-the-art technology, plant experience and availability of local services. This paper describes why, with the rapid change of technology today, Lafarge has moved away from such a strategy, and why the AEG Geamatics B system was selected for our plant at Joppa, Illinois. The emergence of the so-called open-platform, and the evolution of classical DCS suppliers to PLC platforms made this decision possible. Implementation and key features of the AEG system at our Joppa plant are described. Also, issues concerning a corporate automation vision and the potential benefits resulting from standardization in a large organization are examined.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125792918","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":"Re-think, re-engineer, close the gaps: new cement information management solutions","authors":"L. Krings, R. Hantikainen","doi":"10.1109/CITCON.1996.507139","DOIUrl":"https://doi.org/10.1109/CITCON.1996.507139","url":null,"abstract":"The ability to compile, access and analyze critical information is one of the most challenging tasks facing managers of cement plants. Opportunities clearly exist for cost reduction, increased productivity and greater profitability. Increasingly sophisticated process control and plant optimization systems provide raw data in great abundance. Yet, too often, individual process control systems amount to isolated \"information islands\" that lack a means of integrating related data. At the same time, powerful business computer systems are providing an increasingly detailed picture of financial and marketing conditions. New cement-specific information management systems (IMS) are being developed to integrate production, process, energy, environmental, quality and key business information into a consistent relational database. By compiling, condensing and providing access and analysis tools, IMS systems overcome traditional barriers of information access within automation and information systems. Process, production and business managers can have the information they need presented to them in the most useful form on their desktop personal computer. IMS provide tools for plant managers that are unavailable from the process control system. Similarly, they provide a detailed database for use by enterprise managers that cannot be provided by the business control computer system. This way IMS systems close the functional gap between these two systems.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"14 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116881086","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":"Selection and installation of a vertical roller mill for clinker pregrinding","authors":"J. H. Melick","doi":"10.1109/CITCON.1996.507132","DOIUrl":"https://doi.org/10.1109/CITCON.1996.507132","url":null,"abstract":"Roller presses have become well established as a method for increasing the capacity of finish grinding ball mill circuits. While other competing technologies exist, notably the vertical impactor, the vertical roller mill, and most recently the Horomill, none of these has become common in North American cement plants. This paper describes the first application of a modern vertical roller mill as a pregrinder for clinker in North America. The mill has been installed and very recently went into service at Lafarge's Richmond, Canada, cement plant. The reasoning behind the selection of this type of mill is explained, and experience with the installation and commissioning of the equipment is described.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"36 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114491541","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":"Installation of a hydraulic kiln drive to eliminate a resonant vibration problem","authors":"J. Standen","doi":"10.1109/CITCON.1996.506011","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506011","url":null,"abstract":"Large dual electromechanical drive systems have been shown to often experience vibration problems due to both the high inertia of the components of these systems, and the large number of resonant frequencies experienced by these drives. Hydraulic drives, by comparison, are extremely low inertia drives, that have fewer resonant frequencies and benefit from the damping characteristic of the hydraulic oil used to transmit power. Additional benefits include the ability to isolate components while operating the drive and smooth speed control starting at extremely low speeds and full rated torque. This paper outlines the vibration problems that were experienced in a dual drive of a 655' long with 22' and 19' diameter section rotary cement kiln between 1979 and 1993. A number of analytical and empirical studies were performed and various modifications were made or considered to reduce the vibration in the drive train. Finally, in 1994 when the existing drive reached the end of its life, it was replaced with a hydraulic system. The methods both used and considered to reduce the vibration are discussed, as well as the critical elements in deciding on a hydraulic drive and the design issues encountered including questions of drive efficiency, reliability, maintenance and control. Results to date of the hydraulic drive are discussed, including the elimination of the vibration problem and added flexibility in speed control.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"3 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130967151","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 cooler installed at Lafarge Alpena Plant: fuller controlled flow grate (CFG) clinker cooler [cement plant]","authors":"J. Bump","doi":"10.1109/CITCON.1996.506019","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506019","url":null,"abstract":"The decision to replace a major piece of industrial process equipment is not easily arrived at. The short-term needs of the facility must be satisfied as well as the long-term strategies of the organization. The Lafarge Corporation Alpena Plant was faced with such a decision regarding their Kiln 19 clinker cooler. A change in raw materials was expected to increase production rates by 10%. The existing oscillating grate cooler did not have the capacity to handle the additional capacity. Other factors involved in the decision to replace the clinker cooler were escalating maintenance costs, obsolete parts, and poor operational efficiencies. The new clinker cooler utilizes air beam technology and has proven to meet all the requirements of the plant. The anticipated production increase was exceeded without negatively impacting the performance of the air beam cooler. Audited cooler losses were excellent at 207 MJ/t/sub KK/ (49 kcal/kg/sub KK/). Power consumption results were 6.6 kWh/t/sub KK/. Clinker discharge temperatures after the breaker are lower than 56/spl deg/C above ambient. The fuel consumption reduction resulting from the cooler installation was approximately 3%.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131222411","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":"Open networks as a foundation for cement plant automation","authors":"G. Witte","doi":"10.1109/CITCON.1996.507137","DOIUrl":"https://doi.org/10.1109/CITCON.1996.507137","url":null,"abstract":"The objective of this paper is to describe how open network communication can be the basis for a modular control architecture. Benefits highlighted include: increased efficiency for system design, installation, operation and maintenance; superior decision making processes through \"transparent\" data access; lower system life cycle cost; greater flexibility to add to the functions and scale of a control system so as the needs of an enterprise mature, the control system will adapt to the new requirements rather than serve as a barrier.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132900886","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":"Cooler upgrade at Kaiser Cement Permanente Plant utilizing neoteric technology","authors":"C. Schimnosky","doi":"10.1109/CITCON.1996.506020","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506020","url":null,"abstract":"The development of a grate system which would improve air distribution in the critical first compartment area was a major improvement in the operating characteristics of a conventional reciprocating grate cooler. This technology became common in the mid 1980s with many new coolers and retrofits installed in subsequent years. The operational advantages, particularly for retrofit systems, is improved clinker production rate, better energy efficiency, and a reduced vent air requirement for a given clinker exit temperature. With such a list of major improvements, the justification to upgrade for a cement plant with cooler problems is easily seen. The clinker cooler retrofit project at Kaiser Cement's Permanente Plant was not based on the 'traditional' benefits of the new grate systems. The project justification was primarily based upon improved mechanical life hence reduced maintenance costs. Energy improvement was a minor consideration with no significant changes in clinker production rate expected. The results after one year of operation prove this premise to have been correct and the project payback will be achieved as expected.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"18 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"117263632","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":"Electric power deregulation-end of monopoly","authors":"B. Barkovich","doi":"10.1109/CITCON.1996.507136","DOIUrl":"https://doi.org/10.1109/CITCON.1996.507136","url":null,"abstract":"This paper traces the history of the emergence of electric industry restructuring and the deregulation of the power generation sector in California, USA, the first state to adopt a comprehensive retail competition policy for major investor-owned utilities. Since these issues are being hotly debated in many other states, it is useful to understand what has happened in California. While the paper begins by addressing the underlying policy issues, it goes on to discuss the form the new power market is expected to take in California and the objectives that must be met in implementing a new power market that includes competitive generation options for end-use customers and a system of fair, open access to the use of the transmission and distribution systems to bring the power to those customers. Large power customers, such as manufacturers, will be actively involved in this implementation activity. The author has been representing such large customers in this California process.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"26 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114520897","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":"Unbundled products and the potential role of superconducting magnetic energy storage in a competitive electric marketplace","authors":"S. Faber","doi":"10.1109/CITCON.1996.506015","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506015","url":null,"abstract":"Like the natural gas industry before it, the electric power industry is undergoing a fundamental change from a regulated monopoly to a competitive industry where market forces prevail. Today, a retail electric customer still purchases a bundled product (delivered electric energy) from its native electric utility. However, in a truly competitive retail environment, an end-user will be able to competitively source its purchase of various unbundled products from different suppliers. Types of unbundled products that should be available include demand and energy, load following, operating reserves, reactive power, and others. Electric energy storage, which is being developed using superconductor technology, could play a vital role in the developing competitive electric market. Superconducting magnetic energy storage devices can presently store electric energy up to several megawattseconds, but new advances are creating the possibility of storing thousands of megawatthours. This increased energy storage would enable end-users to peak shave and displace traditional sources of power when economically appropriate as is currently done with gas storage.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"10 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126685336","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":"Internet: future communication within the industry [cement]","authors":"C. Field","doi":"10.1109/CITCON.1996.506023","DOIUrl":"https://doi.org/10.1109/CITCON.1996.506023","url":null,"abstract":"The Internet is nearly 30 years old, having been used extensively by academic and government sectors since its birth. Dramatic increases in participation by the industrial sector have been in evidence. However, the cement industry, including cement manufacturers, equipment manufacturers, and related organizations, has not yet become an active participant. Why should the cement industry embrace the Internet? What are the potential benefits, both economic and otherwise? Electronic mail, providing efficient communications among its members, is only one. Others include the sharing of research and promotional information; educational programs (distance learning) on cement and concrete via the Internet; access to timely information, including regulatory and industry information; and electronic discussion groups in which technical problems and ideas can be addressed and discussed. Before participation becomes a reality, several things need to occur. Industry leaders must be convinced that there is sound economic reason to invest the time and money in their companies' participation. They also need to be educated on its use and to see how other related industries are using it. And they need to provide input on the specific types of information and services that are needed. This presentation outlines the potential benefits of the Internet, demonstrates both existing and developing applications, and describes specific efforts toward a unified presence by the cement and concrete industries.","PeriodicalId":373006,"journal":{"name":"Proceedings of 38th Cement Industry Technical Conference","volume":"562 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"1996-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126718324","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}