ROLE OF AUTOMATION & OPTIMISATION

IN CEMENT INDUSTRY

LEARNING IS A
CONTINUOUS PROCESS

ICL DALAVOI

LEARN! LEARN! LEARN! LEARN! LEARN!

 IS IT PLAYING IN VITAL ROLE ? WHERE?
RAW GRINDING CLINKERIZATION

LIMESTONE LOADING
LIMESTONE TRANSPORT
TO CRUSHER

QUARRY CRUSHING

CRUSHER

VRM - II
CEMENT DESPATCH

PACKING

CEMENT GRINDING

WAGON LOADING

BALL MILL

PACKING
MACHINE
ROLLER PRESS
CEMENT
LORRY LOADING VERTICAL
ROLLER MILL
WHY THE AUTOMATION CONTROL
IS REQUIRED IN CEMENT INDUSTRY ?
QUALITY HAS BECOME AN IMPORTANT INDEX FOR CONTROLLING THE
MARKETS
QUALITY CONTROL MEASURE ARE BECOMING MORE STRINGENT AND
SOPHISTICATED NOW-A-DAYS
COMPETITION ON PRODUCT QUALITY.
TO BOOST THE MORALE OF THE COMPANY
TO SAVE ENERGY; POWER; OPERATING COST
LESS IMPACT IN ENVIRONMENT & OPTIMAL RAW MATERIAL USAGE
INCREASE PRODUCTION OUTPUT
BOTH FUEL AND ELECTRICAL ENERGY FORMS 57%OF VARIABLE COST PER
M.TON OF CEMENT
FUEL 36%
ELECTRICITY 26%
 CONSISTENT QUALITY
SAFE EQUIPMENT / WORKING CONDITION
 LOWEST COST OF PRODUCTION
How much can be saved in power and fuel?

• Cost of 1 Kcal /Kg Cl. = Rs. 0.60

• 1 KCal/ Kg Cl Saving ( For 1 million MT Clinker)
• Saving = Rs. 6 Lacs/ Year
• 10 Kcal /Kg Saving = Rs. 60 Lacs/ Year+

•EVERY 0.1 KWH/MT OF OPC ELECTRICAL

ENERGY REDUCTION YIELD SAVING OF
RS. 3.50 Lacs/ year

•( For 1 million MT Clinker)

 Total Variable Cost of Production Per MT of
OPC

14 % 19 %
5%

POWER
FUEL
26 %
36 %

Raw Materials Fuel Power Stores& Spares packing materials

•MINES TO PACKER- DCS/PLC
•-MINES - SURFACE MINER
•CRUSHER - CBA
•LIMESTONE STOCK PILE - STACKER / RECLAIMER
•RAW MILL - CBA/ XRF/ PSA /MICROSCOPE
•BLENDING AND STORAGE SILO - BMA/ XRF/ PSA /MICROSCOPE
•KILN-PROCESS CONTROL AND OPTIMISATION ( FUZZY LOGIC)
•CLINKER -XRF
•CEMENT MILL-XRF/ PSA /MICROSCOPE
•PACKING PLANT - AUTO CHECK WEIGHING
WEIGH BRIDGE
 Industrial Automation

Automation is encompassing virtually every

walk of life.

Automation solutions are required right from

agricultural to space technology.

Plant Automation is the necessity for the

manufacturing industry to survive in today’s
globally competitive market
 What is Automation ?

Automation is basically the delegation of human control

function to technical equipment for

•Increasing Productivity
• Increasing Quality
• Reducing Cost
• Increasing Safety in working conditions
 History of Automation

Distributed Control Systems

Programmable logic controller
Electronic Control using Logic Gates
Hard wired logic Control
Pneumatic Control
Manual Control
 Manual Control

Allthe actions related to process control are taken by the

operators

Drawbacks

Likely human errors and consequently its effect on

quality of final product

 The production, safety, energy consumption and usage of

raw material are all subject to the correctness and accuracy
of human action.
 Pneumatic Control

Industrial automation, with its machine and process control,

had its origin in the 1920s with the advent of "Pneumatic
Controllers".
Actions were controlled by a simple manipulation of
pneumatic valves, which in turn were controlled by relays and
switches.

Drawbacks

• Bulky and Complex System

• Involves lot of rework to implement control logic
• Longer project time
 Hard wired logic control

The contactor and Relays together with hardware timers and

counters were used in achieving the desired level of automation

Drawbacks

• Bulky panels
• Complex wiring
• Longer project time
• Difficult maintenance and troubleshooting
 Electronic Control using Logic Gates

 In 1960s with the advent of electronics, the logic gates started

replacing the relays and auxiliary contactors in the control
circuits.
The hardware timers & counters were replaced by electronic
timers
Advantages
•Reduced space requirements
•Energy saving
•Less maintenance & greater reliability
Drawbacks
•Changes in control logic not possible
•More project time
 ELECTRONIC CONTROL
SYSTEM
Hard Wired Programmable

Program

PROG.CONTLR

# Memory
 PROGRAMMABLE LOGIC
CONTROLLER/DCSs
In 1970s with the coming of microprocessors and associated peripheral
chips, the whole process of control and automation underwent a radical
change.

Instead of achieving the desired control or automation through physical

wiring of control devices, in PLC/DCS it is achieved through a program or
say software.

The programmable controllers have in recent years experienced an

unprecedented growth as universal element in Industrial Automation.

It can be effectively used in applications ranging from simple control

like replacing small number of relays to complex automation problems
 Advantages of PLC/DCSs

 Reduced space
 Energy saving
 Ease of maintenance
 Economical
 Greater life & reliability
 Tremendous flexibility
 Shorter project time
 Easier storage, archiving and documentation
Industrial Automation
Components …

• Field Instruments
• Control Hardware
• Control Software
Automation : Typical installation . . . .
SCADA Software

Communication Cable

Control Hardware
Control Panel
Field Cabling

Junction Box

Field Cabling

Sensors Placed in the field

Automation : Advanced Technology . . . .
SCADA Software

Communication Cable

Control Hardware
Control Panel
Field Bus Network

Field Bus Scanners

Field Cabling

Smart Transmitters Placed in the field

 Sensors ( Field Instruments )

Sensors with transmitters are the field devices placed in

the field who actually sense the parameter and send the
analog signal to the control hardware.
The analog signals used are Ohm (RTD), mV
(Thermocouple), 4-20 mA, +/-10 V, etc
 Widely used Sensors ( Field
Instruments )
RTD : Output in Ohms (Temperature)
Thermocouples : Output in mV (Temperature)
Pressure Transmitters : 4-20mA, 0-10 V …..
Flow Transmitter : 4-20mA, 0-10 V …..
Level Transmitter : 4-20mA, 0-10 V …..
Conductivity meter : 4-20mA, 0-10 V …..
Density meter : 4-20mA, 0-10 V …..
pH transmitter : 4-20mA, 0-10 V …..

And Many more

Leading Manufacturers in
Sensors
( Field Instruments )

Fisher Rosemount
Yokogawa
Anderson & Housers
Radix
ToshBro
 Control hardware

• Standalone PID Controllers

• PROGRAMMABLE LOGIC CONTROLLER/DCSs

(PLC/DCS)

• Distributed Control System

 Standalone PID
Controllers

These are the independent small hardware units

which caters requirement of closed loop controls in
the process.

These hardware can be installed in field or in control

room. These hardware can be connected on the
network.

Currently the controllers are available with 100s of

segment and programming patterns
 Typical Installations using PID
Controllers
Controllers placed in field

RS-232

RS-485 Bus
Leading Manufacturers in PID
Controllers
Yokogawa
ABB
Moore
Eurotherm
ASCON
Chino
Bells
Fuji
 PROGRAMMABLE LOGIC
CONTROLLER/DCSs

Now a days PLC/DCSs are the most widely used

control hardware in control applications. The
applications ranges from standalone system for
CNC machines to Hot swappable Redundant System
for Critical Process Control
 What Constitutes A
PLC/DCS ?
The PLC/DCS is programmed interface between the
field I/p element like limit switches, sensors, push
button and the final control elements like actuator,
solenoid/control valves, drives, hooters etc

PLC/DCS consist of
Input Module
CPU with Processor and Program memory
Output module
Bus System
Power Supply
 Configuration of PLC/DCS :
Modicon
Built in display for I/O Programming Terminal PC Connection
(in-rack, AS-i) and Diag

8 Analog Inputs 1
Analog Output

I/O Modules
Up/Down Fast
Counter

Up Counter TSX37-22

Unitelway Port for connection PCMCIA communications port

of up to 5 Slaves
PCMCIA memory expansion port
 Configuration of
PLC/DCS : Siemens

CPU

I/O Modules
External Power
Supply
 Configuration of PLC/DCS :
Allen Bradley

CPU

I/O Modules
Power Supply
 Distributed I/O
Modules
PLC
/DC
S

Distributed I/O scanner

Data Communication Bus

Distributed I/O modules

 Hot Redundant System Configuration

TAPS
SPLITTERS
Remote
I/O Network
FIBER OPTIC LINK
 Networking of
PLC/DCSs
Supervisory HMI

Modicon : Modbus +, Uniteleway, Ethernet

Allen Bradley : DH+, DH485, Ethernet, Control Net,
Devicenet
Siemens : Sinec L1/L2/H1, Profibus
Programming Languages
in PLC/DCSs

Ladder Logic ( LAD/LD )

Structured Text ( ST)
Instruction List ( IL )
Sequential Function Chart ( SFC )
Function Block Diagram ( FBD )
 Supervisory Control & Data
Acquisition Software
Features of typical SCADA software
• Dynamic process graphic
• Real-time and Historical trending
• Alarms
• Recipe Management
• Security
• Device connectivity
• Script for logic development
• Database connectivity
Some of the Leading SCADA
Software
• Wonderware : InTouch
• Intellution : Fix DMACS
• Merz : Aspic
• Allen Bradley : Rsview
• Siemens : WinCC
• GE Fanuc : Cimplicity
• KPIT : ASTRA
 Role of Engineers In
Industrial Automation

• Designing of the Automation system

• Erection and Commissioning
• Maintenance and Troubleshooting of existing system
 Job Prospect for Fresher

Today management of almost all manufacturing

units are going for industrial automation to
survive in globally competitive market. Most of
these industrial units are looking forward for
trained engineers in the field of industrial
automation.
Since they are thinking about more accuracy,
productivity in less time & with minimum
manpower , It’s a golden opportunity to prepare
yourself to take on this task.
 Current Situation

Automation is a high growth sector globally

hence it is essential to all professionals and
students to have practical knowledge about the
hardware and software used in Industrial
Automation.
 Control Systems Types

 PROGRAMMABLE LOGIC CONTROLLER

 Distributed Control System
 PC- Based Controls
 PROGRAMMABLE LOGIC
CONTROLLER/DCS
PLC/DCS
 Sequential logic solver
 PID Calculations.
 Advanced Subroutines
 BIT Operations.
 Data Transfer.
 Text Handling.
 PROGRAMMABLE LOGIC
CONTROLLER
Applications :
 Machine controls, Packaging, Palletizing, Material handling, similar
Sequential task as well as Process control
Advantages of PLC :
 They are fast and designed for the rugged industrial environment.
 They are attractive on Cost-Per-Point Basis.
 These Devices are less Proprietary ( E.g.. Using Open Bus Interface.)
 These Systems are upgraded to add more Intelligence and Capabilities
with dedicated PID and Ethernet Modules.
Disadvantages of PLC
 PLC/DCS were Designed for Relay Logic Ladder and have Difficulty
with some Smart Devices.
 To maximize PLC/DCS performance and Flexibility, a number of
Optional Modules must be added
 PROGRAMMABLE LOGIC
CONTROLLER/DCS
PLC/DCS Types
 Nano (Small)
 Micro (Medium)
 Large

Basic criteria for PLC/DCS Types

 Memory Capacity
 I/O Range
 Packaging and Cost per Point
 PROGRAMMABLE LOGIC
CONTROLLER/DCS

Components
 Central Processing Unit (CPU)
 Input Output Modules
 Power Supply
 Bus system
 PROGRAMMABLE LOGIC
CONTROLLER/DCS
Central Processing Unit
 It is a micro-controller based circuitary. The CPU consists
of following blocks :
Arithmatic Logic Unit (ALU), Program memory
Process image memory (Internal memory of CPU)
Internal timers and counters
Flags
 CPU performs the task necessary to fulfill the PLC/DCS
funtions. These tasks include Scanning, I/O bus traffic
control, Program execution, Peripheral and External device
communication, special functions or data handling
execution and self diagnistics.
 PROGRAMMABLE LOGIC
CONTROLLER/DCS

Input module
 These modules act as interface between real-time status of
process variable and the CPU.
 Analog input module : Typical input to these modules is
4-20 mA, 0-10 V
Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple
(mV)
 Digital input module : Typical input to these modules is 24 V
DC, 115 V AC, 230 V AC
Ex. : Switches, Pushbuttons, Relays, pump valve on off
status
INPUT MODULES MOTORS ON
DIGITAL SIGNALS
/OFF STATUS ie ‘0’ OR ‘1’
SIGNAL LEVEL
OFFICIALLY ISOLATED INPUTS
Eg:
WET SIGNALS DRY SIGNALS
MCC SIGNAL FIELD INSTRUMENTS
PCC SIGNAL PRESSURE SWICHES
HT BOARD SIGNAL FLOW SWITCHES
FIELD PANELS LEVEL SWITCHES
WEIGHFEEDERS SPEED SWITCHES
TIMERS TEMPERATURE
KILN FEED SYSTEM SWITCHES
COAL FEED SYSTEM LIMIT SWITCHES
PUSH BUTTONS PROXIMITY SWITCHES etc.
ACTUATORS
CONTROL VALVES
ANALOG INPUT SIGNALS

TWO/FOUR WIRE TRANSMITTER

TEMPERATURE
PRESSURE
FLOW
LEVEL
SPEED
VIBRATION
GAS ANALYSIS
ACTUATORS
CONTROL VALVES
WEIGHING SYSTEM
POSITION
SOUND LEVEL
VOLTAGE
CURRENT
POWER
POWER FACTOR
FREQUENCY
 PROGRAMMABLE LOGIC
CONTROLLER/DCS

Output module
 These modules act as link between the CPU and the output
devices in the field.
 Analog output module : Typical output from these modules
is 4-20 mA, 0-10 V
Ex : Control Valve, Speed, Vibration
 Digital output module : Typical output from these modules is
24 V DC, 115 V AC, 230 V AC
Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump
valve on off control
 DIGITAL OUTPUT SIGNALS

DIGITAL OUTPUT MODULES

THE OUTPUT MODULES CONTROLS
THE ON/ OFF STATUS OF THE USER’S
OUTPUT DEVICES.
OUTPUT IS OPTICALLY ISOLATED WITH
FUSE AND OUTPUT STATUS
INDICATION.
IT CONTROLS
MCC FOR MOTORS
PCC FOR MOTORS
HT FOR MOTORS
FIELD DEVICES
ACTUATORS
CONTROL VALVES
SOLENOIDS
ALARMS
HOOTERS
ANALOG OUTPUT SIGNALS
CONTROL VALVES
WEIGH FEEDERS
THYRISTOR DRIVES
AC VFD
ACTUATORS
ETC.
 PROGRAMMABLE LOGIC
CONTROLLER/DCS

Power Supply
 The power supply gives the voltage required for
electronics module (I/O Logic signals, CPU, memory
unit and peripheral devices) of the PLC/DCS from the
line supply.
 The power supply provides isolation necessary to
protect the solid state devices from most high voltage
line spikes.
 As I/O is expanded, some PLC/DCS may require
additional power supplies in order to maintain proper
power levels.
 PROGRAMMABLE LOGIC
CONTROLLER/DCS

Bus System
 It is path for the transmission of the signal . Bu system is
responsible for the signal exchange between processor
and I/O modules
 The bus system comprise of several single line ie wires /
tracks
 PLC/DCS Cycle

 Sense the Input

 Process the Logic
 Give Output

Programmable
Controller/DCS

Inputs Outputs

Machine
or
Process
 PLC/DCS Signal Flow
Input Module Processor Memory Output Modules

Input Data Output

Image Table Image Table
I:0/6 O:0/7
I:0/6
O:0/7
I:1/4 O:1/5

Input Devices Output Devices

Ladder Program

I:0/6 O:0/7

I:1/4 O:1/5
I:1/4 O:1/5

Programming Terminal
 PLC Architecture Evolution
• Mid - 1970s : Discrete Machine Control

Programming
Terminal

Connection is Point to Point

PLC/DCS
Programming Language :
Connection is Point to Point
- Relay ladder logic
- Flexibility in altering
Control system operation
I/O
 PLC Architecture Evolution
• Early - to - Mid 1980 : Discrete and Process Control

MS - DOS
Reasonable Computer
Running PLC/DCS
Programming Software

PLC/DCS
Programming Language :

- Ladder Program
- PID
- Data Storage
I/O
 PLC Architecture Evolution

• Late 1980’s to early 1990’s : Discrete and Process

Control Windows

PC running
PLC/DCS Programming Software
Connection in networked allowing
Multiple PLC/DCS

PLC/DCS PLC/DCS

PLC/DCS became a part of the

developing enterprise resource
I/O system
 PLC/DCS Architecture
Evolution
Today : Distributed I/O
Modules
PLC
/DC
S

Distributed I/O scanner

Data Communication Bus

Distributed I/O modules

 PLC/DCS Architecture
Evolution
Today : Hot Redundant System

TAPS
SPLITTERS
Remote
I/O Network
FIBER OPTIC LINK
 PLC/DCS Architecture
Evolution
Today : Ethernet Technology in PLC/DCS

Workstation Workstation Workstation Workstation

Switched Hub

Controller

Controller
Controller Controller
 PLC/DCS Architecture
Evolution
Today : Wireless communication
PLC/DCS

Wireless Modem

Remote
Platform

Wireless Modem

PLC/DCS

HMI PC
Display
 PLC/DCS Systems of various vendors

Siemens
 S5 -110U, 115U, 135U
 S7 - 200, 300, 400
Allen Bradley
 Micrologix 1000, 1200, 1500
 SLC 5/01, 5/02, 5/03
 PLC/DCS 5/10, 5/25 and 5/40
Modicon
 Nano
 Micro
 Premium
 Quantum
 PLC/DCS Programming Standards

The open, manufacturer-independent programming

standard for automation is IEC 61131-3. You can thus choose
what configuration interface you wish to use when writing your
application :

 Ladder Diagram
 Instruction List
 Function Block Diagram
 Sequential Function Chart
 Structured Text
 PLC/DCS Selection Criteria

 Cost of hardware, software, Integration Engineering,

Design, Installation, Start-up and Commissioning, Validation
documentation and Execution, Training, Spare parts,
Maintenance, System service contract and system life
cycle.
 Reliability, Flexibility, Scalability and Validatability.
 Ease of Database configuration, Graphics development,
Interlocks and Batch processing.
 Integration of High-level Application.
 Control Philosophy for Centralized versus Remote Operator
Console or both.
 Compliance with an Industry batch standard such as ISA
SP88 and new Communication Protocol.
WHY SHOULD WE PROPOSE A SUITABLE CONFIGURATION OF CONTROL SYSTEM?
CBA X-RAY KSS FLC

BUS

PC PC PC PC PC PC

I/O I/O I/O I/O I/O I/O

FIELD FIELD FIELD FIEL FIELD FIELD

D
CONFIGURATION OF CONTROL SYSTEM

siemens
CONFIGURATION OF CONTROL SYSTEM

ABB
CONFIGURATION OF CONTROL SYSTEM

TATA
CONFIGURATION OF CONTROL SYSTEM

AB
CONFIGURATION OF CONTROL SYSTEM

ABB
CONFIGURATION OF CONTROL SYSTEM

TATA
CONFIGURATION OF CONTROL SYSTEM

ABB
 MITSUBISHI
CONFIGURATION OF CONTROL SYSTEM
•IN MINES, SEVERAL MODERN METHODS ARE BEING ADOPTED BY
COMPUTER SOFTWARE FOR REGIONAL MINE PLANING DEPOSIT
ASSESSMENT AND EVALUATION THROUGH COMPUTERISED GEO-
STATISTIC SOFTWARE.
•MODERN MINING TECHNIQUES USES CONTINUOUS SURFACE MINERS
FOR SELECTIVE MINING FOR QUALITY CONTROL.
•CONTINUOUS SURFACE MINING BY CONTINUOUS SURFACE MINER
HAS BECOME VITAL FOR COMPLICATED MULTI BEDDED DEPOSIT.
•THERE ARE VARIOUS TYPES AND MODELS
THE FIRST MODEL WIRTGEN GmbH
THE SECOND MODEL M/s. KRUPP mbH
THE THIRD MODEL M/s. VOSET ALPINE OF AUSTRALIA
 IS IT POSSIBLE FOR QUALITY
CONTROL BEFORE STACKER ? CROSS BELT ANALYSER
Mix HGLS LGLS LS •CBA PERFORMS A NON DESTRUCTIVE ELEMENTAL
LS ANALYSIS OF THE MATERIALS PASSING THROGH IT
•THE ANALYSIS IS PERFORMED USING A METHOD
CALLED PROMPT GAMMA NEUTRON ACTIVATION
ANALYSIS (PGNAA)
CRUSHER •ALL ELEMENTS RESPOND TO NEUTRON
BOMBARDMENT BY EMITTING A UNIQUE GAMMA
CBA RAY SPECTRUM
•THE CBA DETECTS THE MAGNITUDE AND
QUANTITY OF THE DIFFERENT GAMMA RAY
ENERGISES AND INFERS ACCORDING TO
ELEMENTAL COMPOSITION OF THE MATERIAL
•THE ANALYSIS RESULTS ARE AVAILABLE ONCE

PC PER MINUTE AND ARE IN THE FORM OF WEIGHT

PERCENT OF OXIDES
PLANT OPCON STACKER •THE FLOWING ELEMRNTS ARE ANALYSED
•CALCIUM - CaO
•SILICON - SiO2
MINES OPCON
•IRON - Fe2O3
•ALUMINIUM-Al2O3
WITH THIS INFORMATION CBA CAN
CALCULATE THE FOLLOWING PARAMETERS •MAGNESIUM-MgO

•LIME SATURATION FACTOR - LSF •TRICALCIUM ALUMINATE FERRITE-C3F •MANGANESE-MnO2

•SILICA MODULUS - SM •POTASSIUM-K2O

•ALUMINA-IRON RATION-IM
•DICALCIUM SILICATE -C2S
•TRICALCIUM SILICATE-C3S
•DICALCIUM FERRITE-C2F
•TETRACALCIUM ALUMINAL FERRATE-C4AF
•SODIUM-Na2O
•PERCENTAGE LIQUID-%
•SULPHUR-SO3
•BURABILITY INDEX
•CHLORINE-CL
•BURNABILITY FACTOR
•LOSS ON IGNITION - LOI STOCK PILE CONTROL
•PERCENT MOITURE
 WHAT IS AVAILABLE FOR RAW MILL O/L ONLINE
QUALITY CONTROL ? CROSS BELT ANALYSER
•CBA PERFORMS A NON DESTRUCTIVE ELEMENTAL
ANALYSIS OF THE MATERIALS PASSING THROGH IT
Mix IRON •THE ANALYSIS IS PERFORMED USING A METHOD
HGLS CLAY
LS ORE CALLED PROMPT GAMMA NEUTRON ACTIVATION
ANALYSIS (PGNAA)
•ALL ELEMENTS RESPOND TO NEUTRON
BOMBARDMENT BY EMITTING A UNIQUE GAMMA
RAY SPECTRUM
•THE CBA DETECTS THE MAGNITUDE AND
QUANTITY OF THE DIFFERENT GAMMA RAY
ENERGISES AND INFERS ACCORDING TO
ELEMENTAL COMPOSITION OF THE MATERIAL
•THE ANALYSIS RESULTS ARE AVAILABLE ONCE
CBA PER MINUTE AND ARE IN THE FORM OF WEIGHT
PERCENT OF OXIDES
•THE FOLLOWING ELEMRNTS ARE ANALYSED
•CALCIUM - CaO
•SILICON - SiO2
PC Raw mill •IRON - Fe2O3
•ALUMINIUM-Al2O3
OPCON •MAGNESIUM-MgO
•MANGANESE-MnO2
WITH THIS INFORMATION CBA CAN •POTASSIUM-K2O
CALCULATE THE FOLLOWING PARAMETERS
•SODIUM-Na2O
•LIME SATURATION FACTOR - LSF •TRICALCIUM ALUMINATE FERRITE-C3F
•SULPHUR-SO3
•SILICA MODULUS - SM •TETRACALCIUM ALUMINAL FERRATE-C4AF
•CHLORINE-CL
•ALUMINA-IRON RATION-IM •PERCENTAGE LIQUID-%

•DICALCIUM SILICATE -C2S

•TRICALCIUM SILICATE-C3S
•BURABILITY INDEX
•BURNABILITY FACTOR Raw mix control
•LOSS ON IGNITION - LOI
•DICALCIUM FERRITE-C2F
•PERCENT MOITURE (CBA )
 IS ANY ALTERNATE METHOD
AVAILABLE FOR ON LINE RAW MILL O/L CONTROL ?
Mix IRON
LS HGLS CLAY
ORE

PC
Raw mill BMA
OPCON
HOW THE RAW MILL OUTPUT QUALITY IS CONTROLLED
IN OFF LINE? •THE FOLLOWING
ELEMRNTS ARE ANALYSED
•CALCIUM - CaO
Mix IRON •SILICON - SiO2
LS HGLS CLAY
ORE •IRON - Fe2O3
•ALUMINIUM-Al2O3
•MAGNESIUM-MgO
•MANGANESE-MnO2
•POTASSIUM-K2O
•SODIUM-Na2O
•SULPHUR-SO3
•CHLORINE-CL

sampler

PC
XRF Sample Raw mill
preparation
 IT IS USED ALONG
THE RELIABLE
QUANTITATIVE
PHASE ANALYSIS OF
KEY COMPONENTS
INCLUDING
PORTLANDITE,
CALCIT
,ALITE/BELITE,
GYPSUM AND FREE
LIME IN A VARIETY
OF MATERIALS LIKE
RAW MEAL, CLINKER
AND CEMENT.
1000L CBX
AN OPTICAL MICROSCOPE IS MERELY A SET OF
LENSES ARRANGED SO AS TO PRODUCE AN IMAGE
LARGER THAN THE OBJECT THEREBY HELPING ONE
TO IDENTIFY ITS OPTICAL PROPERTIES AND
DELINEATE ITS FEATURES
QUALITY OF CLINKER AND ITS PERIODIC VARIATION
FOR CONTROLLING COMPRESSIVE STRENGTH OF
CEMENT
28DAYS COMPRESSIVE STRENGTH OF OPC WITH A
DEVIATION OF ± 5 WITHIN SAME DAY OF
MANUFACTURE
THE ARTICLE HIGHLIGHTS THE DIFFERENT METHODS
OF STUDY OF SAMPLE PREPARATION IMPORTANCE OF
MINERALOGY AND MICROSTRUCTURE OF LIMESTONE
, MORPHOLOGICAL AND MICRO STRUCTURAL
STUDIES, OF Portland CEMENT CLINKER AND ALSO THE
TECHNIQUES DEVELOPED FOR THE PREDICTION OF
28-DAY COMPRESSIVE STRENGTH. FROM THESE
STUDIES , IT HAS BEEN CONCLUDED THAT OPTICAL
MICROSCOPY IS A SIMPLE AND IN EXPENSIVE QUALITY
CONTROL TOOL AND IS AN AID FOR QUICK
DETERMINATION OF QUALITY OF CLINKER, RAW
MATERIAL EVALUATION AND ITS PERIODIC VARIATION
FOR CONTROLLING COMPRESSIVE STRENGTH OF
CEMENT
SIZE OF PARTICLES AFFECT THE PROPERTIES OF
POWDERS IN MANY WAYS .
IT DETERMINES THE SETTING TIME OF CEMENT THE
HIDING POWDER OF PIGMENTS THE ACTIVITIES OF
CHEMICAL CATALYST
SO IT IS ESSENTIAL TO MEASURE COMPLETE
DISTRIBUTION OF POWDER
THERE ARE TWO TYPES OF MEASUREMENT:
•DRY METHOD IN POWDER FORM IN DRY
DISPERSING UNIT
•WET METHOD WITH WATER IN WET DISPERSING
UNIT
Auto lab
PSA
OPTIMISATION-FUZZY LOGIC-LINKMAN

Economic Process Optimizer

Reaching new levels in process optimization

There is a need for tools that bring cement plants to their optimal
• Kiln feed rate Vs Dosing valve position
• Poldos bin level Vs Silo extraction valve
•GCT pressure Vs ESP fan damper / speed
•PH outlet pressure Vs PH fan damper/speed
•PC temperature Vs PC Pfister coal feed rate
•kiln hood pressure Vs Vent fan damper / speed
•Cooler grate speed Vs First compartment pressure
•First grate speed Vs Second / third grate speed

OPTIMISATION
•SAVING FUEL (3-5%) AND REFRACTORY 30-50%) : PRODUCTION RATE UP TO 5%

•A FUZZY LOGIC /LINKMAN SYSTEM IS AVAILABLE FOR OPTIMISATION

•CLINKER QUALITY IS DEPENDS UPON KILN STABILITY FUEL EFFICIENCY
•KILN PROCESS IS AFFECTED BY INTERNAL AND EXTERNAL INFLUENCES SUCH AS CHANGING
KILN CONTROL BY VARIOUS OPERATORS KILN FEED PREPARATION AND FUEL QUALITY
COOLER INSTABILITY AND CONDITIONS OF COATING
•ALL THESE FACTORS CONTRIBUTE IN MAKING KILN CONTROL DIFFICULT
•THE MODULE WILL PERFORM OVERALL AND CONSISTENT EVALUATIONS OF PROCESS
CONDITIONS, AND EXECUTE ADEQUATE CONTROL ACTIONS ON A MORE FREQUENT AND
RELIABLE BASIS THAN HUMAN OPERATORS
•A FUZZY LOGIC AUTOMATIC KILN CONTROL MODULE IS USED WHEN THE KILN HAS REACHED
APPROXIMATELY 70% OF ITS CAPACITY
•RESULT IN GREATER COOLER STABILITY WHICH IN RETURN WILL INFLUENCE THE KILN
STABILITY
•INCREASE THE COOLER EFFICIENCY WITH INFLUENCE THE KILN STABILITY
•INCREASE THE COOLER EFFICIENCY WITH STABLE AND HIGHER SECONDARY AND TERTIARY
AIR TEMPERATURES
•OPTIMIZE THE AMOUNT OF COOLING AIR
•IMPROVE THE MECHANICAL PROTECTION OF THE COOLER AND ITS AUXILIARIES
•SAVING FUEL (3-5%) AND REFRACTORY 30-50%) : PRODUCTION RATE UP TO 5%
CEMENT MILL:
•A FUZZY LOGIC CONTROL SYSTEM IS USED TO:
•MAINTAIN REGULAR QUALITY CONTROL OF THE CEMENT FINENESS
•PERFORM PROPER ON LINE CONTROL ACTIONS OF THE SEPARATOR SPEED AND TH
MILL FEED IN ORDER TO ACHIEVE CORRECT CEMENT QUALITY AND MAXIMISE
PRODUCTION
•USING FUZZY LOGIC FOR AUTOMATIC CEMENT MIL CONTROL WILL RESULT IN
•IMPROVED STRENGTH OF CEMENT PRODUCED
•MORE UNIFORM QUALITY OF CEMENT PRODUCED
•AN INCREASE IN GRINDING CAPACITY OF THE MILL BECAUSE OF LOWER
RECYCLING RATES AND CONTINUAL MAXIMUM FEED
 KILN SHELL SCANNER
310 360 410 DEG C

SHELL COOLING BLOWERS

SLIP

POWER SAVING
LONG LINING LIFE
AUTO CONTROL
BRICK MANAGEMENT
SLIP MEASUREMENT
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 Your decision to use
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o
your most profitable ever p

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PROFIBUS CONVERTERS
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 MIS-DAILY PRODUCTION REPORT
MIS-MONTHLY PRODUCTION REPORT
MIS-DAILY PRODUCTION REPORT

MIS-YEARLY PRODUCTION REPORT

MIS-DAILY POWER REPORT
MIS-MONTHLY POWER REPORT
MIS-YEARLY POWER REPORT

MIS-DAILY SPECIFIC POWER REPORT

MIS-MONTHLY SPECIFIC POWER REPORT
MIS-YEARLY SPECIFIC POWER REPORT
LET US GO TO NEXT INTERESTING SESSION--- OK!

THANK YOU

?
 BE HAPPY
WISH YOU ALL THE BEST FOR
YOUR LEARNING JOURNEY