The cement industry Our expertise in You need to reduce your consumption to be consumes 1% of world energy efficiency more competitive and respond to

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2 The cement industry Our expertise in You need to reduce your consumption to be consumes 1% of world energy efficiency more competitive and respond to your energy sustainable development objectives. We recommend energy audits helping you modernise your installations to reduce your energy consumption by up to 5% 2

3 Benefiting from the dynamic economies of emerging regions, the cement industry has shown steady growth and record production levels. With such a promising future, signifi cant investments will be required to increase current production capacities and to meet new environmental and energy constraints. You want to follow market developments To respond to customer expectations, you have numerous challenges: - Build new production units while optimising your investments. - Improve quality and reduce operating costs of existing installations. - Achieve your sustainable development objectives by reducing greenhouse gas emissions and energy consumption and by applying specific measures for the safety of man and the environment. We can help you achieve your objectives Experts in systems architecture design, automation, process control and energy efficiency, we have been developing performance and cost-optimised solutions for the cement industry for many years. These solutions meet the needs of Production as well as Engineering and Maintenance, enabling them to concentrate on their core activities and achieve their specific objectives. Countries Billion tons have cement industry Global cement operation. production in

4 e D e s i g n n e w c e m e n t p l a n t s a t m i n i m u m c o s t Cost control on new site development and existing site extension is a key issue based on strategic choices for the future. Synergy of tools Our solutions are based on a suite of integrated tools for optimising the design, monitoring, and management of your processes for maximum productivity. They use the highest-performance components and software on the market to meet criteria of reliability, durability and profi tability of your investments. Open communication network Architectures based on Ethernet TCP/IP provide the greatest openness and transparency at all levels of the enterprise. Ethernet simplifi es your overall communications infrastructure by expanding the horizon of components and innovation, and it provides consistency and simple integration of factory systems with business level communications. 4

5 Chang SiYong Electrical and Automation Engineer, Lafarge, Shui-Dujiangyan Don t waste time designing everything Our automation architectures and their specific functions are tested, validated, and documented. These proven solutions help you save time (and money) from design to commissioning. And don t do the same thing twice With our structured design tools and dedicated cement object libraries, you reuse best practices in the context of new installations and factory modernisation or extensions. The Schneider Electric system has helped us considerably reduce programming and installation time, to control and secure these phases and consequently to minimise delays in commissioning. The integrated process control oriented function library is comprehensive and in phase with Lafarge methodology and specifications. The Schneider Electric open process control system itself generates a significant proportion of the PLC and HMI programming. On its own it eliminates most bugs and reduces development time. average return on investment for clinker process control and energy management systems. 5

6 J.J. G. Plant Manager, Brazil Existing cement plants are running at or close to full capacity to answer to the insatiable demand of the growing markets. Vijeo Citect provides us the best information to expand our production with little or no leeway. And to this end, profits are beeing ploughed back into capital expenditure. As profits increase; so does public expectation of the community s health and safety track record. Vijeo Historian is an easy-to-use and secure tool for plant and IT staff to meet the compliance requirements. Beeing diligent in these detail the attractiveness and competitiveness of the company strongly increase. 6

7 e I m p r o v e q u a l i t y a n d p r o d u c t i v i t y The quality of concrete produced by your customers depends directly on the quality of the cement coming from your factories. Malfunctions during production can have serious consequences, leading to production losses and signifi cant fi nancial penalties. To control or even anticipate developments at each stage, to intervene in real time, and to use high-performance management tools are essential in optimising the quality and productivity of your sites. A high quality fi nished product Our process control and optimisation systems are critical in assuring you of the best possible cement quality: - optimising the blend of raw materials, - improving the measurement and control of airflow, temperature levels, weight, pressure, emissions, material balance and energy use, - improving grinding, combustion, and conveying operations, - enhancing the management of field instrumentation. Maintenance, a source of savings Critical point analysis of your process associated with monitoring tools enables anticipation of breakdowns. On one hand you minimise unexpected maintenance operations and reduce the production shutdowns they cause. On the other, you programme your maintenance operations and speed up restart of your installations. Accurate information for good decisions Product quality, optimisation of installations and cost reductions require actions beyond automation and supervision levels. Our Manufacturing Execution Systems (MES) are business intelligence and know-how tools essential in determining opportunities for: - improved production performances, - increased margins and competitiveness. MES solutions enable management, corporate, IT, factory and production to transform factory real time data into business decisions at all enterprise levels. fossil fuels replaced by alternative energy source (coffee bean shells) for cement production in Africa. reduction in electrical consumption by using advanced process optimisation and control. 7

8 e O p t i m i s e e n e r g y p e r f o r m a n c e Cement production accounts for around 1% of the world s energy consumption. As a cement producer, you are under increasing fi nancial and environmental pressures to find ways to minimize your energy use. Optimising your production processes and improving energy efficiency are two ways in which you can achieve real energy savings. electrical consumption in the cement industry is by machines and equipment. Process control and energy effi ciency go hand in hand Grinding is one of the most important steps in making cement. Overgrinding not only reduces the strength of the fi nal product, but it also consumes more energy than necessary. With proper process control and monitoring capabilities, you can ensure a high quality end product with the minimum amount of energy consumed. Consume smarter to save more Reducing energy consumption is a major financial issue. Energy management technologies give you a global view of your electrical installation, allow you to regulate consumption peaks, help detect unusual patterns of consumption, and signal equipment faults. They also help you to measure, monitor and quickly intervene in order to maximise energy reliability and availability. 8

9 J. M. Electrical and Automation engineer CEMEX, Mexico Our electrical consumption information is now available 24/7 on CEMEX s global intranet to everyone who needs it. For our operations areas, the EMS from Schneider Electric is a key information tool that provides instantaneous access to accurate information and also automatically generates energy reports that eliminate the effort and errors associated with manual data recording. We also use EMS information to implement demand and power factor control strategies. Historical data from the Schneider Electric system is very important to our Maintenance Department since detailed operating parameters like voltage, current, demand and power quality, are readily available to our maintenance managers who can use this information to schedule preventive maintenance or, using the power quality and reliability information, target corrective actions to reduce downtime. percentage of production costs that can be attributed to energy (electricity and fuel). Electric motors, a critical target for energy effi ciency Variable speed drives are an excellent way to optimise the energy efficiency of electric motors, like those used for fans, pumps and conveyors throughout the plant. Your benefits are immediate: - Significant energy savings from reduced energy consumption. - Optimised process control thanks to the ability to send real-time feedback to automation systems, thereby improving kiln and mill operations. - Longer motor life and reduced maintenance costs. For permanently available energy Electrical supply failures mean immediate production shutdowns. These shutdowns lose time and money that can never be recovered. And you can t predict when production will be able to restart. Secure power systems based on uninterruptible power supplies are essential to maintaining production during power cuts. 9

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11 e S u s t a i n a b l e d e v e l o p m e n t The cement industry is responsible for 5% of global CO2 emissions produced by man. It is a sensitive industrial sector directly concerned by the problems of sustainable development: climate change, air and water pollution, management of natural resources, health and safety of production personnel. Eric Pilaud Executive VP - Strategy, Customers & Technology, Schneider Electric Global approach: a source of progress We are all concerned by sustainable development. Each of us in our own way can make a positive contribution. You, by taking into account the constraints and objectives of your operation and its effect on the environment. Us, by offering technical solutions that respond to your needs for today and beyond. A major challenge: reduce gas emissions Gas emissions can be reduced by optimising the complete production cycle, notably in the combustion process and by reducing energy consumption. Use of our integrated automation system platforms, associated with 3rd party gas monitoring systems, provides you with real time data on gas emissions. You are able to take proactive steps to reduce gas emissions and protect our environment. Improved security For an industry such as cement, electrical distribution systems must offer a high level of protection for the security of your employees and your equipement. They should be particularly rugged and reliable, operate 24/7 in a difficult environment, and be safe when undergoing routine maintenance operations. The same is true for advanced automation systems, which must assure process operating safety and guarantee optimum work and safety conditions. Schneider Electric deploys action plans to consume better and less. We undertake with our customers to significantly improve their energy efficiency, whether in buildings, factories, infrastructures or dwellings. We also supply products and solutions exceeding environmental compliance requirements. Particularly, for the cement industry, we recommend an energy audit to improve energy efficiency. We help to set up control and management solutions aimed at reducing customer energy consumption by up to 5%. 11

12 S c h n e i d e r E l e c t r i c s o l u t i o n s e Design new cement plants at minimum cost e Improve quality and productivity e Optimise energy performance e Contribute to Sustainable Development Reduction of heat losses by controlling airfl ow, temperature, pressure and energy materials balance. Measurement and control of consumables in the combustion process Hi-performance speed-drives. Energy monitoring and control. Hi-performance speed-drives. Mix optimisation and raw material quality. Energy monitoring and control. Hi-performance speed-drives. 12

13 Flexible control architectures, structured engineering tools and libraries that reuse the best practices for design of new factories, site modernisation or extensions. Management of production to improve adjustments, quality controls and process outputs. Plant energy management and monitoring at each process phase. Gas emission management. Permanent supervision on line. Historic data and reports. Energy monitoring and control at clinker grinding. Hi-performance speed-drives. Permanent monitoring by finished product analysis for optimum quality. Gas emission control and monitoring. The purpose of our solutions? To offer you a complete solution to all issues relating to design, development and trouble-free operation of your production sites. Globally monitored, the process gains in performance, enabling each at their level to work better and with complete confidence 13

14 S c h n e i d e r E l e c t r i c s o l u t i o n s From electrical distribution to MES, our solutions integrate the highest performance tools on the market. Developed by our R&D teams, they are complementary and designed to simplify the work of your designers and improve your productivity at all levels of the cement plant. Power Electrical Distribution Energy Management Critical Power IMCC Services Automation Process Supervision Control Objects Library Database Variables Devices Networks Knowledge Based Systems MES 14

15 T y p i c a l c e m e n t p l a n t a r c h i t e c t u r e s Time can be on your side if you use all the resources available to you to reduce project development lead times. With this in mind, we have designed typical automation and control architectures depending on process complexity and your daily output. They cover the complete production process and adapt to your specific requirements and expectations in terms of installation, production and maintenance. They are tested and validated. You can use them with assurance of total security. Typical cement control system architecture (5,000 to 10,000 tonnes/day) High performance and profi tability. Quality Control Room MES Control Room control, Kiln optimization, Finess Blending control Asset Management Operator working station Remote OWS Internet Historian server SCADA servers Instrumentation Instrumentation Blending analizer Instrumentation Instrumentation Instrumentation Instrumentation Kiln scanner analyzer Vibration Quarry & crusher Raw mill 1, 2, Fuel mil l Kiln 1, 2, Cement mill 1, 2, Packing Electrical Distribution 15

16 P r o c e s s o p t i m i s a t i o n a n d c o n t r o l Total integration in your environment The Schneider Electric solution uses powerful control system solutions associated to integrated engineering and programming tools. Combining innovation and power, this platform responds to critical demands of the cement industry: - use of the highest performance equipment in its category offering high availability functions (redundant systems required for certain kiln applications), - process control and advanced mathematical functions (enabling certain expert functions without external tools), - process simulation (off line) without risk of actual operation, saving time and cost in commissioning, plant expansions or process improvements/modifi cations, - flexible programming languages covering both process engineering and the demands of electrical and maintenance teams. A real view of your process The increasing complexity of factory engineering imposes optimisation of the design phase by modelling an object-oriented structure depending on the real sequencing of the process. Our advanced design and generation software tool integrates numerous controllers and supervision systems in a common database. It structures the factory application according to the process functional diagram and delivers a true distributed control system environment that is fl exible and open. Powerful tools structure and organise the automation application according to real sequencing of operations execution. Site Kiln preheater Kiln Temperature control Instrument Process control and Cement dedicated object libraries are also available. They enable savings in development costs and can be reused for site extensions or design of new factories. Control Object In choosing Ethernet, we favour openness and integration Why use a proprietary communication network when Supervision graphical object Ethernet offers all the performance and security required by critical applications? You no longer face difficulties in integrating specialised third party equipment in our automation systems: expert and optimisation software, weighing, gas emission systems, vibration control, kiln scanning systems, network instrumentation fieldbuses Integrated Object (Profi bus, Modbus, Hart and Foundation fieldbus). Documentation Common object database creation. 16

17 F a c t o r y c o n t r o l a n d s u p e r v i s i o n + M a i n t e n a n c e t o o l s Total control of your production Supervision and control tools enable simple, complete and transparent access to field variables. They offer user-friendly graphic display of all this information. Your operator therefore has a clear view of the process which enables defi nition and implementation of actions to optimise productivity. Performance of our supervision systems is improved by use of multi-cpu or hyperthread technology machines. At startup, the system is automatically able to create separate components across multiple CPUs, resulting in improved performance and stability. Configuration modifications are achieved with minimum interruption. The power of Ethernet and the Web Web servers integrated in the PLC enable remote access to automation and control equipment using a simple navigator. You can create custom Web pages reproducing the structure of equipment or the process and you monitor and when necessary, control its operation. In the case of events, mail servers automatically generate messages to operators concerning variables or alarms. Asset management from instruments and other units (for example motor protection relays) is also possible at any point in the Ethernet network. W e b s e r v e r i n s i d e Custom pages embedded in the equipment reproduce process screens. 17

18 M a n a g e m e n t t o o l s ( M E S ) * Enterprise Portals SharePoint, SAP, HTML-Based Historical Data Historian Management, Reporting MES Logistics and Accounting Business Integration ISA-95, B2MML Suppliers Production Customers Generic Visualisation Analysis Client, Reports MES Algorithm Processing Enterprise Portals SCADA Planning, Operating, Informing Integrated User Experience Plant Integration SCADA, OPC, Historian, LIMS, Manual Custom interfaces SharePoint, SAP, HTML-Based Data repository 3rd Party Databases Quality, Document Management Systems, Dedicated modules for your environment Metrics You calculate and control key indicators in real time: total energy consumption, total fuel consumption, quarry and plant energy efficiency, raw materials use vs. amount of cement manufactured, gas emissions, etc Production You view the image of your process by integrating all variables: raw materials, consumables, energy, waste, emissions, rejects, etc. Quality You control quality of your products throughout the production cycle. You monitor product conformity by integrating data from your LIMS (Laboratory Information Management System) and from on-line analysers: basic mix formulation, kiln supply particle size, mineralogy control, cement particle size. Downtime You analyse production downtime causes in precise, categorised and and user-friendly automatic reports. Tracking You follow your production: dates/product type/ packing information. Maintenance You plan and monitor maintenance operations: equipment use, execution times, number of starts, load factors. Cost By comparing cost and line production information, you assess factory performance. You anticipate trends and take decisions based on real time data. You can also compare data using your financial management software. * Manufacturing Execution System 18

19 Planner You integrate your ERP in factory environment tasks: production orders, maintenance activity, wait times. Knowledge A repository for documents and data that summarises relevant production process information: production incidents, important information, general production data Historian tools All factory equipment generates data. But this data is of no value unless correctly collected and analysed. The Historian software solution assembles data from multiple information sources and, in association with MES systems, generates detailed reports and data helping decision-making. G a s e m i s s i o n r e d u c t i o n Thanks to the openness and flexibility of our solutions, connectivity between automation systems and gas emission monitoring systems becomes simple. Equipment with basic communication functions is easily integrated using an Ethernet router and customisable Web server. In this way you have access to the gas emission system and control its correct operation with the help of graphics generated with a standard Web navigator. And the server function can alert you to any important event. All information collected from this equipment interacts with factory supervision and management systems to monitor, generate reports and, most importantly, take actions in real time. 19

20 E n e r g y e f fi c i e n c y An imperative, reduce your energy consumption Our energy efficiency solutions are based on a global and progressive approach. Global, because they are aimed not only at consumption reduction and cost optimisation but also at energy reliability, availability and quality. Progressive, because, our systems are easily expanded and upgraded according to new plant requirements due expansions or improvements. A high-performance management system Our Energy Management System integrates software and hardware solutions operating on Ethernet networks, where can be distributed throughout a factory or over all installations of a multi-site enterprise. The system permanently monitors key points of the electrical distribution network as well as equipment and material. It delivers relevant information to those who need it, wherever they are located. The combined use of MES (Manufacturing Execution Systems) with the energy management system enables effective decision-making. Together, they offer quick and quantifiable return on investment, often after only a few months. The system is highly flexible and adaptable to your environment and your normal working procedures. In particular it offers: -the world s most highly developed energy-linked instrumentation, - modular equipment easily adaptable to your site developments at minimum cost, - embedded memory to avoid data loss, - compliance with industrial standards and international certifications, - creation of energy quality compliance reports, - low installation and TCO costs. A valuable ally in energy saving and production shutdown reduction Our IMCC (Intelligent Motor Control Center) solutions use the best network architectures, motor protection and variable speed drives. IMCC brings intelligence to motor control: - system availability based on networks with fewer potential failure points, - fewer shutdowns thanks to remote access and improved problem identifi cation, - more information available to aid effective decision-making, - energy savings by use of high-performance variable speed drives, - flexibility of solutions based on multiple networks. 20

21 E n e r g y d i s t r i b u t i o n a n d C r i t i c a l P o w e r Be protected against possible electrical supply failure and assure quality and availability of electrical energy. A permanent operation reliability approach When planning your cement plant, it is essential to precisely analyse your requirements and anticipate future developments so as to make the right electrical installation design choices and to avoid undersizing equipment. Schneider Electric is the worldwide leader in Electrical distribution, providing best-in-class solutions for the most exigent requirements: - protection and control of LV power circuits, - MV secondary distribution products, - MV components, - MV/LV equipment and systems. Secured energy For the most critical parts of the process, the use of uninterruptible power supplies (inverters) and/or generator sets is the only way of avoiding all risk of production shutdown. Our high-power uninterruptible supplies are recognised for their qualities and ease of integration in any industrial high-performance electrical distribution system. They integrate control and supervision functions enabling operation self-monitoring, battery state indication, etc. Uninterruptible power supplies for all enterprise levels: from simple control devices to large power supply systems and complex IT solutions. Hexe girxivw * jegmpmx} Qemrjveqi0 hexe girxivw0 jegmpmx} gsrxvsp vssq Gsrxvsp vssq Wivzivw0 vsyxivw0 rix{svow0 hiwoxstw Tperx jpssv Ts{ivmrk hizmgiw iuymtiqirxw0 tvsgiwwiw W}wxiqw erh wspyxmsrw Rix{svo YTW0 Hiwoxst YTW Ps{ irh YTW w}wxiqw XZWW 1 Xverwmirx Zspxeki Wyvki Wyttviwwsvw 21

22 A c o m p l e t e r a n g e o f d e d i c a t e d s e r v i c e s Project management Looking for commitment on our part for your modernisation projects and new plants? You can count on the experience and involvement of our teams and the support of our partners. Using the specific tools we have developed (engineering and design software, migration tools and dedicated libraries), production shutdowns are restricted to the minimum. We help you improve the plant performance, proposing solutions for the modernization of your current control and electrical distribution systems and providing solutions for your new installations. And we can provide longer term support by: - handling design and deployment of a standardised solution and tools on a project that can be applied in other sites, - associating maintenance of the installed base with planned modernisation. Advice and expertise Need a new method, or skills on a point considered particularly important? Our experts and consultants offer to help you analyse what exists and to defi ne and deploy specifi c solutions. For operation In operations or preventive maintenance, our tools and methods enable you access to accurate diagnostics from our systems: electrical distribution equipment, intelligent motor control centers, communication networks, speed drives, process control systems. In case of intervention, a detailed and commented report is provided following our technical visit. For modernisation and new projects - At pre-project, our consultants help you assess opportunities, define solutions, estimate budgets and propose deployment techniques. With diagnostics, recommendations and results of feasibility studies, you validate and secure your project. - For project steering, our experts provide support in preparing specification studies (software standardisation, architecture diagrams, etc.), assistance on solution deployment and results checking. Schneider Electric training centres worldwide 22

23 Training Does safety of your operation and plant performance depend on constant adaptation of the skills of your personnel? We can help you: Identify your training requirements by systematic analysis of levels and functions of your teams, propose training modules covering your installed automation equipment, follow up acquisitions by ongoing training, offer training modules designed to suit your timing and locations. You have available over 50 training centres with high technology learning tools, professional trainers expert in both industry and teaching, standard or customised courses on-site or on our installations. Replacement parts and repairs Does your competitiveness depend on your reactivity to breakdowns and malfunctions? We can help you limit downtime periods. From our stock we can supply you with tested and certified replacement parts compatible with your installed equipment. By contract you can stock on your installations replacement parts which remain as our remote stock until be effectively used. Finally, you have also available a strong distribution channel network, present worldwide, that opens to you another access point to our products. Maintenance contracts Do you count on long-term reliability and performance of your installations? Let s build together your custom services contract. Services pack or made-to-measure: - telephone support for priority access to our experts centre, - web access to benefit from latest version software, - stock of our branded replacement parts on your installations or in our warehouses, - assurance of on-site assistance within a guaranteed time. We help you anticipate technical risks and perform essential modernizations by taking account of equipment obsolescence. It avoids penalizing production shutdowns. You control maintenance costs by optimised replacement parts stock management. Operation operating people dedicated solutions in the world Modernisation 23

24 Schneider Electric Industries SAS Bd. Franklin-Roosevelt Due to evolution of standards and equipment, characteristics indicated in texts and images F Rueil-Malmaison in this document are binding only after confirmation by our departments. FRANCE Publication: Schneider Electric Design: pemaco Tél. : +33 (0) Photos : Médiathèque Lafarge - Hamilton De Oliveira, Jean-Philippe Mesguen, Nian Zeng, Christelle Bitouzet, José Antonio Rojo, Samuel Ashfield, Alam Beg Imtiaz Print: 03/2008