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PROCESS SOLUTIONS FOR CEMENTPlantPAx® distributed control system enhanced functions that improve productivity and optimize energy consumption.
Faced with the challenge of dramatically reducing emissions while addressing an increasing global demand for cement, producers are looking to technology to help them reduce costs per ton, monitor energy use, maintain quality, and optimize operations.
Integrated, information-enabled solutions support improvements from system design through maintenance, and from quarry through packing and dispatch.
The PlantPAx® distributed control system (DCS) enables the seamless integration of a modern DCS with plant-floor and business systems, helping you to realize efficiencies and optimize processes across operations.
Delivering efficiencies
precisely where you need them
2Delivering efficienciesPG 2
Process control challengesPG 3
The connected cement plantPG 4
Why PlantPAx®PG 5
Process control benefitsPG 6
Unique demandsPG 7
A modern approachPG 8
Logic instructionsPG 9
Process solutionsPG 10
PROCESS CONTROL CHALLENGES IN CEMENT PLANTSCement plants face specific and intense challenges. Harsh operating environments and complex processes aren’t made easier with disparate systems and lack of real-time information.
At the same time, aging equipment and workforce dynamics can affect productivity negatively.
LACK OF STANDARDIZATION
MAINTENANCE EFFICIENCY
WORKFORCE SKILLS GAPS
EXCESS TIME AND ENERGY CONFIGURING
CONTROL SYSTEMSOPERATOR
PRODUCTIVITY
3Delivering efficienciesPG 2
Process control challengesPG 3
The connected cement plantPG 4
Why PlantPAx®PG 5
Process control benefitsPG 6
Unique demandsPG 7
A modern approachPG 8
Logic instructionsPG 9
Process solutionsPG 10
4
IoT Gateways
In the connected cement plant, integrated smart systems and advanced analytics enable end-to-end operational visibility and support better decision-making.
The connected cement plantIntegration and visibility drive productivity and performance
Enterprise and Business Applications
Integrated Process Control and Power
Condition Manager
IoT Platform / Analytics and Visualization
Remote Monitoring
Process Optimization
Third Party applications & systems
Supply Chain Simulation
Mobility
4Delivering efficienciesPG 2
Process control challengesPG 3
The connected cement plantPG 4
Why PlantPAx®PG 5
Process control benefitsPG 6
Unique demandsPG 7
A modern approachPG 8
Logic instructionsPG 9
Process solutionsPG 10
Why PlantPAx® distributed control system? The PlantPAx distributed control system uses a common automation platform for seamless integration between critical areas of your plant.
A modern DCS connects process, discrete, power, information and safety control into one plant-wide experience. As such, it delivers the productivity and efficiency improvements you’re looking for. It provides the real-time information you need to actively reduce energy consumption, and significantly lowers total cost of ownership.
Crusher Raw Mill Coal Mill Alternative Fuel
Kiln & Cooler
Cement Mill
Packaging / Shipping
Sales by Category
Total Energy Usage – July 2018Daily Peak Demand in July
Actual .vs Baseline
TOTAL
###
COMPARED TO TARGET
OVER/UNDERTARGET
#
####
#
##
###
###### ###Some words here
Sales by Category
Total Energy Usage – July 2018Daily Peak Demand in July
Actual .vs Baseline
TOTAL
###
COMPARED TO TARGET
OVER/UNDERTARGET
#
####
#
##
###
###### ###Some words here
Sales by Category
Total Energy Usage – July 2018Daily Peak Demand in July
Actual .vs Baseline
TOTAL
###
COMPARED TO TARGET
OVER/UNDERTARGET
#
####
#
##
###
###### ###Some words here
5Delivering efficienciesPG 2
Process control challengesPG 3
The connected cement plantPG 4
Why PlantPAx®PG 5
Process control benefitsPG 6
Unique demandsPG 7
A modern approachPG 8
Logic instructionsPG 9
Process solutionsPG 10
The PlantPAx® DCS leverages the top advancements in process controlALARM MANAGEMENT Standards-driven approach
PlantPAx DCS is built on a complete state model defined in ANSI/ISA-18.2-2016, Alarm Management Systems for the Process Industries.
• Includes mechanisms that support alarm rationalization and proper alarm suppression
• Helps operators focus on the most critical issues
DEVICE INTEGRATION Delivers plant-wide information
PlantPAx DCS delivers an immediate and measurable impact on asset availability, operational efficiency, and energy management.
• Integration of drives, instruments and intelligent electronic devices
• Reduced integration cost of disparate systems
• Safe monitoring of energized devices on operator screens
• Intuitive functionality improves flexibility and security
OPERATION FUNCTIONSProvides more flexibility and security
With PlantPAx DCS, all objects operate within a pre-defined set of commands.
• Different functions can be granted or denied access based on a defined user group
• Fully configurable to enable highly-defined security schemes
• Out of service option for decommissioned equipment
6Delivering efficienciesPG 2
Process control challengesPG 3
The connected cement plantPG 4
Why PlantPAx®PG 5
Process control benefitsPG 6
Unique demandsPG 7
A modern approachPG 8
Logic instructionsPG 9
Process solutionsPG 10
MEETING THE UNIQUE DEMANDS OF CEMENT PRODUCTIONCombining our significant industry experience with the direct input of users themselves, our cement system drives consistent configuration across the plant.
Incorporating model predictive control technology, our solution is specifically designed to connect processing areas and improve operational efficiencies in cement production:
• Provides kiln, crushing and grinding optimization
• Reduces process variability, increases overall production and reduces energy cost per ton
• Enables better compliance with environmental regulations
• Helps increase throughput and improve process/ operational consistency
7Delivering efficienciesPG 2
Process control challengesPG 3
The connected cement plantPG 4
Why PlantPAx®PG 5
Process control benefitsPG 6
Unique demandsPG 7
A modern approachPG 8
Logic instructionsPG 9
Process solutionsPG 10
Simpler and more intuitive operation
Intuitive alarm area
Simplified color scheme for better operator awareness
Effective displays
Library of contextual display
Objects to drive productivity
Working area: Alignment to industry standards
Language switching
A modern approach for the cement industry EFFICIENT DESIGN AND OPERATION PlantPAx® DCS provides a standard approach across engineering, operation and maintenance, reduces engineering risks and is easier to operate, maintain, and modify.
IMPROVED OPERATOR SITUATIONAL AWARENESS
8Delivering efficienciesPG 2
Process control challengesPG 3
The connected cement plantPG 4
Why PlantPAx®PG 5
Process control benefitsPG 6
Unique demandsPG 7
A modern approachPG 8
Logic instructionsPG 9
Process solutionsPG 10
Logic instructions and faceplates for cement usersWe make it easy for cement producers to design and develop the most appropriate systems. Our reusable libraries of content enable the development and deployment of these systems in a timely and cost- effective way.
Our application content helps engineers to create automation projects from a standardized, life-cycle-managed, application-focused library. This content includes code and faceplates suitable for cement applications -- including motor control, drives, valves and sequencing control -- delivered in such a way that you can build precisely what you need quickly and efficiently.
ROLE-BASED/EASY-TO-OPERATE FACEPLATES The faceplate enables operators, maintenance personnel, engineers, and others to interact with an instruction instance, which includes a view of its status and values.
Operator tab
Maintenance tab
Trends tab
Diagnostics tab
Alarm tab
Help file
Reset and acknowledge alarms
Permissive and interlock objects
Motor
ControlProcedural
ControlValves Cross
Functional
9Delivering efficienciesPG 2
Process control challengesPG 3
The connected cement plantPG 4
Why PlantPAx®PG 5
Process control benefitsPG 6
Unique demandsPG 7
A modern approachPG 8
Logic instructionsPG 9
Process solutionsPG 10
The connected cement plant PROCESS SOLUTIONS TO MEET YOUR NEEDSOptimizing and maintaining critical operations in your cement plant demands expertise and modern, integrated automation solutions.
We offer a wide range of process solutions that safeguard your operations and meet your economic and performance requirements. These solutions are scalable, flexible, and easy to integrate, helping you to increase productivity, lower costs, reduce energy consumption, and improve safety.
To learn more, visit our website.
10Delivering efficienciesPG 2
Process control challengesPG 3
The connected cement plantPG 4
Why PlantPAx®PG 5
Process control benefitsPG 6
Unique demandsPG 7
A modern approachPG 8
Logic instructionsPG 9
Process solutionsPG 10
Publication CEMENT-BR002A-EN-P - May 2019
PlantPAx DCS, FactoryTalk InnovationSuite, and FactoryTalk OperationSuite are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.
Copyright © 2019 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
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Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444Europe/Middle East/Africa: Rockwell Automation NV, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846
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