Cement plant case studies and insights

Just as we are now all convinced that digitalization is the next big thing in the cement industry, it turns out a few young engineers already pioneered software to optimise cement production back in 1969.

Industrial automation systems improve business productivity and financial results. Such systems are usually procured as a capital expenditure designed to meet a set of requirements that, if delivered, should produce a return on investment (ROI) sufficient to justify the expenditure. The problem is, however, as capital projects have finite budgets, the set of capabilities implemented is often limited.

It’s a growing problem for many countries around the world: used car tyres piling up as authorities struggle to find effective disposal solutions. Heating and power plants can help solve the problem by burning tyres and other solid materials, creating energy for use in households and industry, including cement production.

Orient Cement shares how the installation of two hydraulic roller press systems supported the efficiency and sustainability objectives of their Karnataka plant.

Cement plant operators around the world know the importance of keeping maintenance time and costs to a minimum, while running at maximum efficiency. Plants with the SF™ and the Multi-Movable™ Cross-Bar® coolers can now use a new type of grate that reduces power consumption and simplifies maintenance.

As cement producers continually seek reduced energy consumption and lower maintenance costs, two emerging trends are changing the face of cement production: the use of grinding stations that support variable feed materials and more widespread use of vertical roller mills (VRMs). Cement producers in India, Nepal and Bangladesh demonstrate the success of using VRMs.

Clinker is the most expensive and carbon-intensive ingredient in cement. Optimizing cement’s clinker factor has therefore become a key target for cement companies looking to reduce their carbon emissions – as well as support their bottom line. At Holcim Germany’s cement plant in Höver, a modern automated sample preparation system is providing the foundation for an efficient and consistent process that delivers optimal product quality with lower environmental footprint.

Safety is critical in any pyro process. Incorrect or inadequate monitoring of explosive gases can create unsafe working environments, endangering plant employees. It may also damage or destroy costly machinery, resulting in long-term production shutdowns.

Industries across the planet are stepping up environmental efforts, all while keeping an eye on the bottom line – and cement plants are no exception to this trend. Many cement plants are looking to minimise their environmental footprint through the use of alternative fuels, such as tyres, and while this can be environmentally beneficial, the higher sulphur content of these alternative fuels results in substantial challenges.

Fuller was looking for a partner to install its new cross-bar cooler; Capitol Aggregates was eager to expand capacity. It was a very cool match.

The Fuller Service Projects team (CSP) took over customer support after installation of a new production line and helped Titan gauge and address priorities.