In its endeavor to reduce energy use, Jura implemented a complete automation solution from ABB for its plant in Italy. The primary goal of this automation project was to reduce energy demand in all areas, combined with the search for the optimal operating point, consistent with productivity and quality targets, while staying compliant with environmental emission limits.
Energy optimization - a key success enabler for the cement industry
Cement producers are large consumers of thermal and electrical energy, which globally is available at steadily increasing costs. Efforts to reduce demands by using higher efficiency equipment and substituting fuels and raw materials to lower production costs are some efforts in recent years to offset this increase in energy costs. Finding the optimal operating point within the boundaries of dynamically variable constraints of quality and productivity targets, depends on the right price mix of fuels and timely purchase of electrical energy, while constantly reducing demand for these resources.
Cement manufacturing is a complex and energy-intensive process. A key operation in this process is the conversion of ground raw materials (CaCO3, clay and/or shale) into clinker in the kiln. This operation, involving intensive heating up of raw materials in a conventional control of the cement kiln requires an experienced operator who constantly interprets process conditions and makes frequent adjustments to set points established by the controller. This task is made more difficult by complex responses, time delays and interactions between individual process variables. As a result, conventional kiln control operates at temperatures higher than optimum, leading to unnecessarily high energy usage.