Improve The Quality Of Your Processes

For cement manufacturing plants to operate profitably, well-functioning processes are essential. At all costs, expensive equipment standstills must be avoided. Complete transparency is a necessary first step in achieving this, as it will lead to increased productivity as well. That’s where CEMAT, the Siemens integrated process control system created especially for the cement industry, comes in. Alpha Drives Ltd. can provide this to our customers to help them save resources and increase productivity .

Experienced In Intelligent Process Control For Over 20 Years

Specifically created for the cement industry, CEMAT based on SIMATIC PCS7 has been well-received and proven over many years in challenging environments. Together with major cement producers across Ireland Alpha Drives Ltd. built up a vast body of knowledge in the field of cement manufacturing, which they used to build the CEMAT control system. Based on the widely used SIMATIC PCS 7 process control system, CEMAT provides the cement industry with innovative, cost-effective, and future-proof solutions through an open architecture.

Performance Enhancement – Lifelong

Better plant performance is made possible with CEMAT, both now and in the future. You can simply manage every process, from resource management to productivity control, from raw material extraction and crushing to final product packing, all thanks to a near real-time overview. You receive condensed data, such as that related to energy, manufacturing, and quality, which helps you make the best choice possible every time. To manage the production as efficiently as possible, you may obtain all essential production data with a few mouse clicks, including the status of running machines, fault and alarm information, maintenance information, etc.

Dependable Standards And Specialized Knowledge

Based on Siemens’ over 40 years of experience and partnership with the top cement firms globally, CEMAT is currently proving its worth in more than 900 installations. CEMAT provides a solid foundation for a productive plant because it combines standardised hardware and software with in-depth process knowledge.

Utilizing SIMATIC PCS 7, CEMAT

Because CEMAT’s technological foundation is SIMATIC PCS 7, it breaks new ground in every aspect and presents new potential in the cement production industry. Additionally, this industry-leading process control system stands out from the competition thanks to its standardised hardware and software, which offer the greatest levels of reliability across all industries. The CEMAT system is fully customized to satisfy the needs of the cement industry and comes with all required parts.

Additional Advantages For Plant Managers

Additionally advantageous to plant operators are increased comfort, adaptability, future-proofing, and broad compatibility with legacy installations:

  • Decentralised I/O approach: Modularize your plant to achieve maximum flexibility.
  • I/O that is freely configurable: Take advantage of late signal binding and incredibly comfortable software wiring.
  • Basic integration of devices: In place of trial and error, use plug-and-produce.
  • ­Standardised solutions: Provide complete cost control over the whole lifecycle of the facility.
  • SIMATIC Compact Field Unit (CFU): Provide the groundwork for field-level digitization

Feature Highlights Of CEMAT V9.0

  • CEMAT latest version V9.0 includes additional SPC features, new interlock modules, zoom function for faceplates and many more enhancements. Considerations for work in a virtual environment have been a strong focal area in the development for V9.0.
  • With the new feature to cascade up to four SPC-Material Managers it is now possible, to define up to 96 materials.
  • Furthermore the new Material Managers are able to communicate from PLC to PLC so that material assignment needs to be done only once, centrally, for the entire plant.
  • New SPC-recipe module for data type “BOOL”
  • The newly made symbols for all the SPC-recipe modules can be freely placed wherever required in any process picture so that recipe data is – without complicated engineering – visible wherever necessary.
  • The new zoom function allows the operators to adjust the faceplate display from 50% to 200% of the original size.
  • All modules have a new „Quitt-“output which can be used to pass on “hardwired” the operator’s acknowledgement action, i.e. to an external device.

Calculate Your Profits

For maximum productivity in the production of cement, precision dosing, pinpoint measurement, and exact monitoring of output rates are essential. Efficiency in measurement and control boosts productivity, saves time, decreases waste, and increases availability. Siemens offers a full range of control and instrumentation for processes that are made to integrate easily.

Measure Every Output Value Carefully While Making Cement.

Precise dosing, pinpoint measurement, and exact monitoring of production rates are all essential for consistent cement manufacturing. You know that measurements taken by Siemens are accurate. Your advantages include increased burning process efficiency and more consistent kiln operation. Your cement operation’s environmental friendliness can also be supported by lowering air pollution and harmful exhaust emissions.

Siemens offers a wide range of products and solutions to meet the special needs of cement operations with its revolutionary measuring equipment. Siemens’ portfolio includes an appropriate measuring instrument for each stage of production across the cement process, including production sensors, weighing and dosing systems, process analytics, and process instrumentation.

Process Analytics

System For Analysing Gas:

Gas analytics is essential to many cement industry applications, and its significance should not be understated.

Siemens provides a broad range of gas analysis solutions to address these crucial issues, including process optimisation, environmental protection, and health and safety concerns.

Monitoring Of Emissions:

The significance of precise gas analysis has increased with the introduction of carbon trading programs and stricter regulatory requirements. It is essential to monitor exhaust gases as they exit the stack for the purposes of process optimization and regulatory compliance.

In order to comply with a variety of municipal, national, and international regulations, businesses using secondary fuels must be able to monitor a broad range of gases, including CO, NOX, SO2, O2, dust, HCI, HF, Hg, and THC.

Security

Time is of the essence when it comes to safety. A quick and accurate monitoring of CO or oxygen is required in cement plant sites where coal self-ignition or explosions pose a risk.

The sampling system of conventional continuous gas analysers causes a noticeable delay in processing. As a result, there is a large range between the thresholds for adding inert gas to coal silos or triggering bag filters and electrostatic precipitators.

The time delay of an in-situ laser analyser is zero. Because it responds quickly, thresholds can be set higher. As a result, there are fewer ESP and bag filter visits, and the amount of expensive nitrogen in the coal silos is decreased.

Process Streamlining

Maintaining the lowest possible production costs is a major concern for cement manufacturers. It’s not a simple operation to manufacture clinker when raw materials must be heated to extremely high temperatures. The cost of fuel and coal is constantly rising, and most facilities use a wide range of waste materials and fuels in their kilns, which makes it even more difficult to regulate the burning process.

Continuous gas analysers at key sites have the potential to greatly improve cement process optimisation and lower production costs.

Measuring Instruments

Measurement Of Pressure:

The plant can greatly increase the lifespan of the filter bags inside the filtration plant by installing pressure transmitters, for instance, throughout the baghouse and the preheater. Additionally, it guarantees that the preheater is running as efficiently as possible.

SITRANS P offers the whole spectrum of pressure measurement—absolute, differential, and relative. Apart from excellent measurement accuracy and durability, other distinguishing characteristics are the modular system’s ease of use and practicality, as well as flawless safety.

Measurement Of Temperature:

Temperature fluctuations give rise to early warning signs of changes in process conditions. Temperature fluctuations need to be closely watched in order to prevent damage to production equipment as well as to preserve product quality.

True temperature readings in harsh environments are provided by SITRANS T, a communication-capable device, at locations such the kiln, coal mill, preheater tower, clinker cooler, electrostatic precipitator, and clinker silo.

Measurement Of Flow:

Clinker is ground with additives like gypsum, slag, and lime at the conclusion of the cement production process to create finished cement. This technique increases grinding efficiency while using less energy.

SITRANS F offers a broad range of electromagnetic, Coriolis, ultrasonic, vortex, rotary pistol, and differential pressure flowmeters that are suited for measuring a variety of fluids, ensuring precise and dependable dosing of cement additives.

Measurement Of Level:

For cement quality and productivity to be maintained, it is crucial to maintain the proper quantity of feeding, clinker level, or dosing of clinker, gypsum, and other additives. This applies to coolers, tall silos with wide diameters, and limestone bins and crushers with severe mechanical stress.

With options including hydrostatic, gravimetric, electromechanical, guided-wave, ultrasonic, capacitance, and radar, SITRANS L provides the ideal solution for any application.

Process Protection Sensor Technology

Motion-Detecting:

Many operations rely heavily on bucket elevators and other feed conveyors, thus it’s critical that any incidents like conveyor slowing, halt, bucket loss, or chain breakage are reported right once to the control room. An equipment malfunction can be immediately alerted to by the speed alarm. This makes it feasible for problems to be found as soon as possible, reducing downtime and facilitating quick fault control and correction.

Acoustic Sensors:

There are various SITRANS acoustic sensor types available for material flow and pump monitoring. The SITRANS AS100 is designed to identify variations in high-frequency sound waves emitted by moving objects and equipment. It responds quickly to variations in the flow of solids to alert users to obstructions, missing products, or malfunctioning equipment like burst filter bags. This enables the operators of cement plants to take early preventive measures, avert expensive damage, and provide the best possible exhaust gas filtration.

Systems That Read Codes:

Product or component unique coding is a critical need in contemporary manufacturing systems. Siemens code reading systems are the ideal products for reading and validating 1D/2D codes, such as barcodes and data matrix codes. They also make it possible to track production batches after they leave the production facility.

Vision Detectors:

A whole image processing system for automated object inspection is found in the SIMATIC vision sensor. It is perfect for use in manufacturing, especially in packing, and in hard industrial environments.

Positioners

SIPART PS2 Positioners:

Both rotary and linear actuators can be used with the SIPART PS2 positioners. They perform exceptionally well because of their lower installation costs, easy functional extension with inexpensive option modules, and improved diagnostic capabilities. They may be utilized with even the tiniest actuators. A very extensive list of advancements includes simple connection and very user-friendly higher-level operation and monitoring, to name just a few.

Weighing And Batching Systems

Electronics Weight:

A wide variety of weighing processors for force measurements, hopper, batching, differential batching, bagging and belt scales, and solids flowmeters are available with SIWAREX PLC-based weighing electronics. It is not problematic to fully integrate the SIWAREX weighing modules into the SIMATIC system platform. All of the function blocks needed to communicate with the devices and manage the process are provided in CEMAT.

Load Cells:

SIWAREX mounting elements and load cells have been shown to be suitable and to meet cement process requirements. Because load cells come in a variety of ranges, they can be used with great accuracy and a wide measuring range in nearly any application.

Scales For Belts:

Belt scales are used to measure the feed rate of the limestone conveyer to the crusher and, occasionally, the feed rate after the crusher for inventory purposes. The conveyor belt scales combine a straightforward, drop-in installation, minimal maintenance, and repeatable accuracy for efficient operations. They have a history of reliable performance in challenging conditions.

Solid Flowmeters:

Flowmeters are essential for the continuous in-line weighing of granular materials, free-flowing powders, and dry bulk solids. The sensor heads yield precise, dependable results and are installed outside to the process systems. They can be used for important tasks including blending and batch load-out.