Challenges for the American cement industry

53. Cement Industry Technical Conference IEEE 2011, St. Louis/USA (22.-26.05.2011)

From 22.-26.05.2011 experts from the plants and machinery suppliers meet to discuss current trends and future perspectives on the occasion of the 53rd annual IEEE-IASPCA/IAS conference in St. Louis/USA. During the conference, technical presentations will be given, tutorials will be held and up-to-date equipment will be shown in the associated exhibition.


1 Technical presentations
1.1 Supported by the Environmental, Energy and
Sustainability Working Group

– Pollutant dust suppression

– Alternative method of Hg and THC control using existing cement kiln particulate control equipment

– New control techniques for cement kiln emission control

– Organic Rankine Cycle (ORC) based power plants to utilize low-grade waste heat sources

– Potentials for AFR co-processing

– Reliable kiln inlet gas analysis

– GSA installation at Norcem Brevik/Norway

– How to create optimum aerodynamics for reducing both CO and NOx in in-line calciners

– Gaining visibility and control of raw materials at Lafarge cave-in-rock cement quarry

1.2 Supported by the Power Working Group

– PLC based energy enterprise solutions

– Fully utilizing intelligent electronic device capability to reduce wiring in cement industry distribution substations

– Standard for electrical safety in the workplace and its requirements

– Arc flash protection enhancement and mitigation

– Energy efficiency strategies for the cement industry

– Arc flash hazard assessment in above-ground mining



1.3 Supported by the Automation Working Group

– Considerations in network and automation options for low voltage motor control centers

– Network infrastructure in large integrated control systems

– Increasing data historian efficiency

– Online x-ray diffraction at the Buzzi Festus plant

– PLC based optimization of finish mills


1.4 Supported by the Maintenance and Safety
Working Group

– Lubrication and maintenance for key machines in the cement industry

– Online conditioning monitoring network for critical equipment at Holcim’s Ste.Genevieve Plant

– Wear management program for vertical mills

– Incorporating an advanced maintenance strategy improves equipment reliability and reduces cement plant costs

– The theory and application of acoustic cleaners within key process areas of the cement manufacturing industry and related power generation plants

- Stochastic simulation of system reliability as a tool for maintenance strategic optimization in a cement plant

– Improved maintenance reduces risk, raises profitability in conveyor operations

– How green is your lighting?


1.5 Supported by the General Practices Working Group

– Clinker kiln optimization: pushing your equipment to the limit

– Preheater upgrades

– Cylindrical powder cement cooler automation

– Online analyzer applications and Davenport example

– Central cone silos for cement

– Innovations in storage silo floor design and operation

– Alternative fuels: challenges in receiving, preparation, storage and blending

– A new tool for analyzing grinding efficiency


1.6 Supported by the Drives Working Group

– The use and proper selection of variable speed drives (vsds) for reduced environmental footprint, sustainability and increased plant reliability

– Brush lifting system for wound rotor induction motors

– Electrical AC drive conversion strategies for optimizing cement production - a case study

– Paradigm shift in proper selection criteria of vfd cable for variable frequency drives


2 Tutorials

As in the past years, a number of tutorials are planned, from practice to practice. In a clearly interactive way, up-to-date topics are presented and discussed in smaller groups with a direct possibility for every attendant to discuss an interesting topic at any time and more in depth than it is possible after a technical presentation in a plenary hall.


2.1 Wireless technology for cement plant applications

The tutorial will explore three principle methods to employ wireless technology in a cement plant setting. The first two methods are fairly classical – providing wireless access for port­able HMI stations and wireless connections for classical PLC and PLC I/O. The third method outlines the planning and implementation of a wireless I/O network that utilizes the self-organizing and self-healing features of the wireless nodes. Typical installations and implementation planning and guidelines will be addressed. The tutorial is presented by Proconex (sponsored by the Automation Working Group).


2.2 “Variable speed drives – types, sizing, selection, how to implement into a project”

The tutorial will consist of five sessions of varying durations, totalling approximately six hours, including breaks and questions & answer periods:

Session 1: Overview of Drives (AC, DC) & Applications in the Cement Industry

Session 2: Theory, Construction and Variations of AF LV Drives

Session 3: Theory, Construction and Variations of MV Drives

Session 4: Theory, Construction and Variations of MV Drives (Cont)

Session 5: LV & MV AC Motor Theory, Construction and Application

It is presented by Patrick Brady, PABTech, and Siemens (sponsored by the Drives Working Group).

2.3 The need for an engineered refractory solution to provide for improved plant reliability

The tutorial will focus on the design of monolithic refractory structures, non-destructive testing techniques, and failure mechanism analysis and will be presented by Dr. Greg Palmer of Palmer Technologies Pty Ltd. (Sponsored by the General Practices Working Group).


2.4 Analysis for the design of electrical power systems

This tutorial will include: an overview of electrical power systems studies and methods, load flow and sizing of MV feeders and motor starting studies, short circuit studies and equipment evaluation, overcurrent protection/time current characteristic coordination studies, protective relaying applications, NFPA 70E 2009 overview, arc flash analysis, and harmonics analysis. It will be presented by Joseph Maida, PE, Harvey Hnatiuk, PE, and Justin Alexander, PE (sponsored by the Power Generation Working Group).

2.5 Safety tutorial – MSHA Part 46 Annual Refresher Training

Consulting engineers, vendors, and contractors who work in an MSHA facility but are not directly employed by the facility will benefit from this tutorial. These individuals work for a sufficient time period to require MSHA training (other than site specific training). At the completion of the 8 hour training, attendees will receive a 5000-23 certification of training. The trainer will be Daniel Lowe of Essroc.


3 Environmental Workshop

Under the umbrella of the Environmental Workshop a number of activities are scheduled. On Tuesday, the following presentations are on the agenda:

– CEMs: Installation, operation, and maintenance within the reality of cement plant operations

­– NESHAP control technology implementation strategies: How to match new equipment to existing processes while avoiding problems and pitfalls

– Analyzer experiences: Output accuracy and validation concerns from two cement plants

­– Dust collector performance concerns and prediction monitoring: Can modifications to existing equipment meet the new NESHAP performance expectations?

– Sorbent Trap Myths and Reality: A Review of Data


On Wednesday “Reducing energy consumption: A panel discussion” moderated by Fred Schoeneborn, EPA Energy Star, formerly Global Facilities and Energy Management Coordinator for Mobil Corporation, is on the agenda. Finally, at presentation on “Cement specifications and their impact on sustainability” will be held on Wednesday.


4 Exhibition and plant tours

Up-to-date technology can be seen during two plant tours: The new Buzzi Unicem 7000 t/d Festus/Selma plant (Fig. 1) as well as Holcim’s, 12 000 t/d Ste. Genevieve plant (Fig. 2). Both plants came on line in 2009 and feature the latest in large plant equipment from a vast array of different suppliers and are among the most energy efficient plants in the world today. They are located about 40 miles south of St Louis. About 100 companies are participating in the exhibition. Hospitality suites will complete the networking opportunities during the conference. Additionally, the Chairman of the PCA Board of Directors, Aris Papadopolous, CEO of Titan America, will be addressing conference attendees on Wednesday, May 25 at a Chairman‘s Luncheon.


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