Transforming Cement Production: Embracing Digital Solutions for Industry Advancement

The Internet of Things (IoT) is viewed by several industry sectors as the driving force behind a revolution in manufacturing. The German automation industry’s Industries 4.0 initiative includes IoT as a crucial component. Its goal is to lay out the future path for manufacturing businesses in the era of the Internet. The increasing intelligence of the process industries is a fundamental component. Digitalization helps address industrial issues including the need for more production, efficiency, optimisation, and lifecycle time, and cement firms can benefit from it as well. Alpha Drives Ltd.’s digitalization solutions guarantee the greatest quality while also enabling up to 20% savings in energy and raw materials. We are traveling down the path of digitalization alongside the CEM.

Innovative methods for producing cement that increase sustainability while conserving energy and raw resources

In addition to the strict quality standards, the building sector must deal with concerns like “energy efficiency” and “eco-balance.” This even holds true for less obvious objects like bridges. As with energy-efficient homes, every stage of the building process is being assessed from a sustainability perspective. This covers the production procedures for distinct building materials and each of their constituent parts, which includes cement. There is enormous potential for savings in energy-intensive industrial areas like cement manufacture.

Lower fuel usage is made feasible by an efficient production process. Given the approximate 3 TWh total energy used in Germany’s cement sector, almost 150,000 households might be supplied with the saved energy. Digitalizing operations and process control is the crucial step towards making cement production ultimately as “green” as the final product.

Integrating data in plant engineering

Throughout the entire design phase, Alpha Drives Ltd. Integrated Plant Engineering offers various plant engineering disciplines a constant supply of data tailored to their individual requirements. This linked data provides training in advance and allows users to explore the plant in three dimensions using its digital twin, which was built during the engineering phase before the actual plant was built. Connected data can be used to build automation projects, which eliminate the requirement for labour-intensive human engineering tasks. These extremely integrated data can serve as a source of information for plant maintenance management in the future.

Automation – the rock-solid basis

Automation lays the foundation for the cement industry’s transition to digitalization. Automation can therefore be compared to the brain, which gathers all the data via an intricate web of sensors and instruments acting as the eyes and ears, as well as integrated driving systems acting as the muscles. Only with a strong automation solution is digitalization feasible. This demand is perfectly met by Siemens’ well-proven process control system, CEMAT, which is based on SIMATIC PCS7.

Enhancement of output capacity

 

The ideal method for maximizing production potential in the cement industry is the cutting-edge process control system CEMAT, which is built on the foundation of SIMATIC PCS 7 technology. Even for unique process optimization tasks, all required function components are already present in the system and have been standardized. This includes mill optimization as well as the use of either fossil fuels or alternative fuels to optimize the oven’s fuel supply.
With CEMAT, process control can be made more forward-looking, automatically increasing throughput without sacrificing product quality. High standards for quality can be set, energy and raw material consumption can be significantly decreased, and production can be more loosely structured.

Decades of experience in the cement industry

Our products and solutions for the cement industry incorporate more than 20 years of experience and collaboration with Ireland’s leading cement companies. They are based on proven standards and tailored to the specific demands of your industry.

Advanced Process Control

SIMATIC PCS 7/CEMAT includes a standard library containing a wide range of different types of Advanced Process Control (APC) control functions, making it possible to address the majority of complex closed-loop control tasks in the cement industry. This provides the user with easy access to an advanced functionality at no extra cost. Customer´s expertise can be easily integrated, planning and implementation are minimized and furthermore, the system is modular and open to future extensions and implementation of artificial intelligent solutions.

Kiln Control System

The process of making cement requires a lot of energy and is prone to several unplanned disruptions. Operators must invest a lot of time and energy in process management and keep a close eye on it at all times. Increasing clinker production efficiency and quality is the aim of the Kiln Control System (KCS).

Customer benefits

  • Reduced workload for control personnel
  • Improvement of product quality
  • More efficient use/reduction of the energy consumption
  • Improved lifespan of machinery due to gentler modes of plant operation
  • Improved lifespan of refractory material used for the kiln lining
  • Better compliance with exhaust gas regulations and other environmental requirements
  • Reduction in the number of unscheduled plant downtimes
  • Enhanced reliability: the optimization system ensures that the plant operates more reliably at all times

Mill Control System

Cement plants require a lot of energy for the milling process. Using the Mill Control System (MCS) can result in possible energy savings. The MCS is a software system that uses current plant data (specified measurable values) and a knowledge-based methodology to make inferences about the production facility’s quality levels. This quality metric can only be continuously measured by a laboratory system at predetermined intervals; otherwise, the process optimisation system MCS provides values for it continuously.

Minerals Process Analyzer (MPA)

The Minerals Process Analyzer (MPA) is a long-term system that provides data for additional analysis and assessments. It can be connected with other process control systems, such as SIMATIC PCS 7 CEMAT. Cement makers profit from MPA’s various advantages, which include enhanced productivity through data comparison, cost savings, and improved quality through alert analysis and the integrated report system.

Process simulation

It is possible to combine the cement process simulator with SIMATIC PCS 7 CEMAT, which allows for a realistic reconstruction of a cement plant’s behaviour. Before starting actual production, the digital twin provides virtual commissioning, operator training, and the ability to observe plant behaviour by adjusting process parameters. For cement clients, it means increased efficiency, reduced expenses, and safety.

Operations intelligence

Siemens operations intelligence is a customised solution based on your IT infrastructure and automation systems. The implementation of this technology will facilitate real-time performance management and decision assistance at the upper management level by gathering, analysing, and presenting operational and business data for plant dash boarding.

By using smart and connected field devices, cloud solutions, and real-time plant data, data transparency may assist cement businesses optimise their whole supply chain for cement production as well as the full material value chain. It can also expedite the decision-making process. It improves the visual quality of the cost variables by comparing the assets of the various plants. It goes without saying that Siemens’ cutting-edge solutions satisfy the demands of industrial IT security.

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