Displaying items by tag: monitoring

UK: Holcim subsidiary Aggregate Industries has invested in a new monitoring system from Envirosuite for its Cauldon cement plant in Staffordshire. Called EVS Omnis, the cloud-based environmental management software will collate complex environmental information from surrounding sites outside the plant to facilitate proactive monitoring and management of its impacts. The producer expects to commission the system later in 2022.

Sustainability director Kirstin McCarthy said “Understanding the environment we operate in and the impact we’re having is integral to our business strategy and our commitment to building progress towards a more sustainable construction industry. We know that noise and dust can have an impact on surrounding communities, which is why we’re extremely proud to become the first cement plant in the world to commit to using a complete monitoring solution. EVS Omnis will allow us to continuously monitor at key community locations, 365 days a year. This will help us to not only better understand our operations within the local community but also give us insights into our processes to proactively manage them.”

World: US-based Martin Engineering has announced the launch of its N2 remote monitoring system on European, Middle Eastern, African and South Asian markets. The system's position indicator works with any belt cleaner with a polythene blade, delivering continuous, real time feedback to the user.

Martin Engineering’s Europe, Middle East, Africa and India (EMEAI) regional vice president Robert Whetstone said “With this smart yet simple upgrade, the technology does the legwork, providing real-time data on each belt cleaner blade to give an early indication of when servicing is needed. In the meantime, plant managers can be confident that material carryback, spillage and build-up is being controlled by the belt cleaner so they can keep the plant running to maximise productivity.”

Indonesia: Entsorga has dispatched two Spider bridge cranes and two Pelican feeding and dosing systems for the construction of two new solid recovered fuel (SRF) storage, feeding and dosing systems at Indocement Tunggal Prakarsa’s 11.9Mt/yr Citeureup cement plant in Bogor Regency. The systems will have a total capacity of 50t/hr. An advanced supervision system will monitor and control their 24-hour operation. The Italy-based supplier says that both lines are highly automated and will reduce both CO₂ emissions and fuel consumption.

CEO Francesco Galanzino “The systems will help the cement plant to maintain its 2030 sustainability commitments, in line with the policies of HeidelbergCement who is a real first mover in the path toward sustainability. Such project it is a very important step in a Country where environmental policies are in their early stage.”

India: Shree Cement has hired Denmark-based FLSmidth to carry out its digital transformation. The supplier will install its ECS/PlantDataManagement monitoring system at Shree Cement’s cement plants. It says that the technology will increase efficiency.

Shree Cement’s joint managing director Prashant Bangur said "We are always looking at ways to optimise production, and the decision to apply FLSmidth's information management system to all our sites is a natural next step." Whole-time managing director Prakash Narayan Chhangani said "FLSmidth is a trusted partner for us, as we demonstrated by the milling and pyro order we announced last year. And we are confident that this next step in our digital transformation will prove to be profitable."

US: Conveyor Components Company has announced its launch of Model DB, a conveyor belt rip detector. The equipment relies on a cable pull concept to trip the belt drive. Different microswitch options allow customers to choose from four circuit designs. Thus, instead of shutdown, an alarm response is possible. The supplier says that the technology offers similar performance to embedded coil devices.

Russia: Krasnoyarsk Cement has installed a continuous monitoring system for emission control at its Krasnoyarsk cement plant. It carried out the upgrade under the government’s national Ecology project. The system will transmit daily average emissions data to the Krasnoyarsk Territory Ministry of Ecology and Nature Management. Members of the public will be able to access the submissions on the ministry’s website.

Managing Director Dmitry Kireev said “According to the current legislation, the installation was supposed to start working before 31 December 2028. However, due to the fact that the enterprise is located within the city, we voluntarily assumed increased obligations and launched online monitoring of emissions ahead of schedule."

Holcim Schweiz hit a milestone recently with the aerial drone programme at its Siggenthal cement plant. The project with Voliro, a Switzerland-based technology start-up, has started to use multi-rotor drones to conduct official measurement flights. They used them to take measurements to determine the steel wall thicknesses of the cement kiln and the cyclone preheater. The work has been part of Holcim’s ‘Plants of Tomorrow’ industrial automation plan with unmanned aerial vehicles (UAV). Key features of the particular drones being used are that they can be rotated around all axes by a special rotor system and can even fly upside down.

Holcim has been using drones in and around cement plants for a few years now. When it launched the Plants of Tomorrow plan in 2019, Switzerland-based drone supplier Flyability said that the cement company had chosen its Elios 2 model to perform confined space inspection. Earlier in 2017 another supplier, SenseFly, said that LafargeHolcim Tanzania had been using its fixed-wing products. Holcim is also far from alone in its use of drones. A few examples among many include Cemex USA’s work with Kespry earlier in 2021, HeidelbergCement’s work in North America and Germany in 2020 and 2021 and Votorantim’s testing at its Córdoba and Niebla plants in Spain back in late 2015. 

UAV usage by armed forces dates back to examples like unmanned incendiary balloons being deployed in the 19^th century to Azerbaijan’s reported decisive use of drones in its war against Armenia in late 2020. The current era of industrial UAVs began after 2000 when governments starting issuing civilian permits, miniaturisation occurred and improvements in cameras, sensors and computing power followed. For the mineral processing sector the trend started with drones being used for stockpile management and quarry surveying. At present this is the main area that UAVs are used for by the sector, often coupled with photogrammetry techniques. CalPortland’s Adam Chapman’s paper at the 2021 IEEE-IAS/PCA Virtual Cement Conference described one company’s use of UAVs in the cement industry since 2016, looking at licensing, cost, quality of data, drone technology, fleet management and field experiences.

More recently though, tests of drones used to survey cement plant buildings and structures have started being publicised such as Holcim’s work at Siggenthal. A presentation by consultant John Kline and Chris Place of Exelon Clearsight summarised the use of drones for structural inspection at cement plants at the Global CemProducer 3 webinar in January 2021. The key benefits they promoted of using an UAV in this way were: improved safety because workers have reduced risk from climbing, working at height or in confined spaces; less time to conduct a survey; higher resolution photographs and video; better coverage through grid method surveying; and an overall lower cost. However, on that last point, other commentators have noted that market-leading drones for surveying are relatively expensive and easy to damage. Drones have since been used to start going inside structures at cement plants with Kline demonstrating their use to inspect the condition of refractory within the cooler, kiln, pre-heater and cyclone of a production line at the Global CemProducer 2 webinar in July 2020. HeidelbergCement has also been doing similar things, with an inspection trial using a drone of the kiln at the Schelklingen plant in Germany during the 2021 maintenance shutdown period at the site.

So far the use of drones by the cement industry has mostly been in a surveying or inspection capacity. Given the short time that UAVs have been used like this there is likely to be scope for lots more development both within existing fields and new ones as the sector works out how best the technology can be used. One application we couldn’t find in the research for this short article was the use of drones for security and surveillance tasks at cement plants and quarries although this may be happening already. However, there could be a more active role for drones if or when a company finds a way for them to start making basic repairs or carrying out simple maintenance in those hard to reach areas that drones excel at accessing. Research examples exist of UAVs being used to spray concrete or repair materials onto minor defects in concrete structures. Yet considerable challenges face these kinds of applications such as the weight of a loaded multi-rotor drone or damage from rebound. Before we all get too worried about drones replacing our jobs though it is worth considering that Amazon’s plan to deliver packages by UAV was first announced in 2013 and it still hasn’t happened yet. It may yet, but for now in most situations humans remain cheaper and more practical than robots or drones.

Canada/US: Schaeffler has launched Optime, a condition monitoring system, on the Canada and US markets. The supplier says that the system consists of wireless vibrator sensors, a cellular gateway and a dedicated data collection app. The captured information is then processed and analysed by Schaeffler’s proprietary software and models. This can then be used to improve cement producers’ awareness of possible damage to components such as fans, motors and pumps.

Americas regional manager for condition monitoring and Industry 4.0 service solutions Frank Mignano said “With Optime, comprehensive and automated condition monitoring is now a cost-effective proposition for reliability personnel and facility operators.”

Denmark: FLSmidth has launched an online condition monitoring kiln service. It says it will give plant managers the live insights they need to optimise performance and be proactive with regards to kiln maintenance. The new ‘Online condition monitoring services for kilns’ enables producers to use existing and additional sensors to gather data from equipment on a continuous basis. This data is sent to FLSmidth’s Global Remote Service Centre where it is analysed for early signs of failure. Recommendations and reports covering maintenance issues that need addressing are sent to the customer. The service agreement is available in two packages, based on the customer’s monitoring requirements.

“Digitalisation enables us to help customers develop a data-led proactive maintenance approach, guided by our network of experts,” said Mireia Fontarnau Vilaró, Head of Service Commercial, FLSmidth. “With this service agreement, we are able to collect and analyse data that would not be normally available, giving our customers the opportunity to really get on top of maintenance, improve the life of kiln components and improve their overall reliability.” The equipment supplier says that its service monitors the kiln crank, kiln shell ovality and axial balance, helping customers avoid unplanned downtime through root cause analysis.