Trouble-free cement production

Siemens has been commissioned by Christian Pfeiffer Maschinenfabrik GmbH to supply an integrated drive system and automation technology for a new cement milling factory operated by Cahya Mata Sarawak (CMS) in Malaysia, with a view to ensuring optimum energy efficiency and maximum availability of the new plant. The new cement milling plant is currently being constructed in Kuching, the biggest city on the Malaysian island of Borneo. In conjunction with the already existing clinker production facility (Fig. 1), the new mill is set to be extended to create an integrated cement production plant. With this move, CMS aims to increase its annual capacity by 57 % to 2.75 million tons of cement.

Christian Pfeiffer Maschinenfabrik GmbH from Beckum, Germany is acting in the capacity of general contractor with overall responsibility for the turn-key milling plant (Fig. 2).

The supplied Integrated Drive System consists of low and medium-voltage motors as well as the associated Sinamics drives including the required converter transformer, starter, compensation system and gear- box. The supply package contains a slip ring motor of 5.6 MW for the cement mill’s main drive, and a 500 kW, a 400 kW and a 160 kW motor driven using Sinamics G150 converters for the process gas fan, separator and mill filter fan, respectively. Optimized interaction between the different drive components will ensure energy-efficient operation as well as a high level of fan availability. Siemens has also supplied a Flender girth gear unit (DMG2) including drive couplings and auxiliary drive with extremely high performance density for use in the new plant.

Process control and monitoring are being taken care of by the integrated ­Cemat process automation system. Based on Simatic PCS 7, this allows comprehensive transparency throughout every phase of the cement manufacturing process, making a major contribution towards process optimization. As soon as the milling process has stabilized following commissioning in Kuching, CMS will also be taking over additional control functions using Advanced Process Control technology components, allowing the manufacturer to benefit from a consistently high level of product quality and reduced staffing costs for operating personnel.

Installation monitoring, commissioning and staff training are being carried out on site by Siemens Malaysia.


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