Automation has transformed multiple industries, contributing to better visibility, efficiency, economy, and waste reduction, among other benefits. Automation has also improved cement industries for value generation and cost, and ensures predictable/consistent end products and processes. Indian cement industry only lags behind China in terms of the quantity of cement produced annually and is ahead of Japan and the USA. In-plant automation in the cement industry yields multiple benefits in cost, efficiency, speed, waste reduction, and enhanced satisfaction of all stakeholders involved.
Relevant New Automation Technologies at Different Process Levels in the Cement Industry
Cement plants benefit from smooth process flows and sophistication with automation. The benefits are also realized in quality, logistics, speed, energy, and environmental effects. A well-executed automation system can transform the economy of manufacturing cement, and the technical aspects of performance. Automation reduces manual intervention, provides for consistent quality, and maximizes the yield. Since the investment towards automation can be substantial, due diligence must be exercised for selecting the appropriate automation vendor/supplier. Some of the new automation system technologies for cement production plants (at different levels) are:
· The process Digital Controllers/Process Logic Controllers systems and the Discrete Controllers. While the PLCs are restricted to stand-alone machineries/systems, the discrete controllers involve multiple systems. These are usually the Level 1 systems.
· The Level 2 systems are for sub-processes. They contribute towards improving yield and are equipped with modern sensors. They may be used for controlling the raw mixes, and grades, and monitoring stockpiles, among other processes. Examples include the PGNAA (Prompt Gamma Neutron Activation Analysis) and XRF (X-ray fluorescence) systems.
· The Level 3 automation systems coordinate processes for the entire plant and reduce costs. They may be implemented to control quality and/or maximize capability and yield.
· The Industrial Information Technology concept is also emerging. It can link the different systems and applications seamlessly and ensure better utilization of real-time or historical data. Asset life cycle ensures all-time production ability. The other operation dimension of the IT systems supports producing and delivering quality products consistently.
Benefits of In-Plant Automation for the Cement Industry
Automation can smoothen the complex cement manufacturing process, enhance efficiency, and reduce costs. The investment results in substantial savings over a period. It also reduces carbon emissions in sub-processes including cleaning, mixing, crushing, and logistics. Below are the important benefits of in-plant automation for the cement industry.
Better Decision Making: The cement market will continue on its growth spree in the coming future. It is expected to grow at approximately 22% (and even more!) in the coming 3 decades. The distributed control automation systems bring real-time data to the fingertips of decision-makers. The information solutions are scalable and can span across multiple plant departments. They ensure information-based decision-making and scalability.
Amalgamation of Intelligence: The automated intelligent subsystems smoothen the production with little or no manual input. For instance, the radio frequency instruments and readers, controllers for load scales, and motion controllers are placed alongside PLCs in racks. They ensure swift and timely communication for efficient process control.
Maximizing Production: Maximum, high-quality, and consistent production ensures greater profitability. The latest information-based predictive control systems help achieve consistent performance without compromising quality. The automation system adds intelligence and support to ensure peak performance and system stability.
Environment Benefits: Automation reduces waste and ensures better efficiency in energy consumption. It creates favorable compliance and ensures a greener planet for coming generations. Reducing emissions is the need of the hour, and automation is a necessary tool to achieve it.
Yard Management: Automation benefits facility management and logistics. For instance, it uses the new RFID (Radio Frequency Identification) technology and systems to track the goods and manage the vehicles. It is a marked improvement over the traditional manual process. The Cement industry can benefit from better transparency and accountability, lesser turnaround time, and efficient resource utilization.
Process Efficiency: Automation systems can improve the efficiency of sub-processes, and enhance agility. For instance, an automation weighbridge automates the weighing process for entry and exit and can even replace the booth operator. The tech/sensor-enabled weighbridge solutions can simplify the weighing process. The steps involved are improved with automated lights, sensors, and signals to enhance accuracy and reliability. The automation provides for easy and hassle-free management of the plant/facility. It also ensures efficient workforce deployment and prevents unnecessary utilization of manpower.
Real-time Automation: the new PLCs integrate the functionalities like real-time process control and decision-making. For instance, the sensors placed at critical and relevant stages of the process can provide continuous inputs from the field instantaneously. The output devices receive these signals and act accordingly. These sensors and the input/output instructions are managed by PLC for the conveyors, crushers (primary/secondary), stackers/reclaimers, and other systems and machinery. The real-time end-to-end system management skills of automation are greatly appreciated for agility and waste reduction, among other benefits.
Safety Management: Automation information and sensor systems reduce the risks of untoward incidents at the plants. Other systems, including GPS and RFID, can automate movements in and out of the facility and monitor the vehicles and men. The data is recorded and updated instantaneously and can be made available through tiered access.
Compliance: Automation systems ensure accurate compliance with the existing laws and regulations. An automation system’s intuitive dashboard can generate the data, documents, and reports necessary for compliance procedures. The feature is much appreciated by the client companies and regulators alike. The systems can flag and report irregularities and deviations from the norms, which ensures timely adjustments and corrections. Automation systems improve compliance in areas including processes, workforce/workplace safety, and environment protection, among others.
Conclusion
In-plant automation is available for multiple levels of in-plant cement manufacturing. From the sub-processes to the system-wide automation, the new technologies can help the industry in many areas depending on the investment made. The new systems improve process efficiency while generating crucial data and reports that support decision-making. The advantageous information, sensors, and information technology-based systems can ensure long-term sustainability, favorable economics, maximized quality outputs/products, and customer satisfaction.