Expert system for optimization of cement mills

Summary: The milling process in cement plants is extremely energy-intensive, accounting for nearly 45 % of the overall electrical energy requirements. Siemens has designed an expert system which uses actual plant data to make precise predictions about quality parameters for a production plant, and which can be integrated into the existing PCS-7 control system with no additional hardware. Mill control can be optimized on the basis of predicted quality parameters, which in turn reduces energy consumption and has a positive influence on the plant’s cost-effectiveness and availability, as well as on product quality. The first pilot project was conducted at the Südbayerische Portland-Zementwerk in Rohrdorf.

1 Portland cement production in Rohrdorf

At the Südbayerische Portland-Zementwerk in Rohrdorf, the raw materials extracted from the neighboring quarries that are necessary for producing Portland cement clinker are stored in a blending bed hall and then ground into raw meal in a raw mill. In the rotary kiln the raw meal is then burnt to cement clinker, which is the basic material for all types of cement. The plant has four ball mills for a total output of around 270 t/h. Grinding is performed in a ball mill with steel balls of different sizes. Depending on the type of cement, materials such as...

Related articles:

Issue 05/2013

High quality cement for Burj Khalifa and other projects

The contract for the National Cement Co. (NCC) cement plant (Fig. 1; Table 1) was signed in September 1974 and the plant was opened on 01.08.1978 by HH Sheikh Rashid Bin Sayeed Al Maktoum. It was...

more
Issue 6/2017 INSTITUTE OF POWER PLANT ENGINEERING AND HEAT TRANSFER

Development of a linear statistical model for the cement milling process

1 Introduction The investigation on the correlation between milling process parameters and energy consumption is well known [1]. Hitherto the following empirical differential equation dW = –?C ?...

more
Issue 10/2016 FLSMIDTH | ANNA UNIVERSITY | IIT-MADRAS

Tube mill drive systems – a review

1 Introduction In cement production, tube mills with multi-chambers are traditionally used in either open or closed circuit operations. The process of cement grinding basically includes a grinding...

more
Issue 5/2017 GEBR. PFEIFFER SE

Gebr. Pfeiffer announces a ready2grind system with MVR mill technology for LafargeHolcim Colombia

LafargeHolcim Colombia has awarded Gebr. Pfeiffer an order for the modular ready2grind cement grinding system that includes the latest innovative MVR technology for vertical roller mills....

more
Issue 3/2016 MU?LA SITKI KOÇMAN UNIVERSITY

Grinding and classification performance evaluation and modelling of an industrial-scale horizontal roller mill process

1 Introduction Cement is conventionally produced in multi-compartment type ball mills which is a energy intensive process [3]. Typical energy consumption of the grinding stage of cement production is...

more