The typical processes in a cement plant are :
- Extractors are used for Quarrying.
- Crushers are used for crushing huge rocks into coarse raw material.
- Blenders and Mixers are used to mix the ingredients in correct proportion.
- Grinders mix the ingredients well to be heated in the rotary kiln.
- The heating and cooling is carried in rotary kiln.
- Finally, the cement is packed and dispatched using conveyor belts or transportation vehicles.
Equipment are monitored because
01. Equipments are over-maintained for higher productivity.
02. Equipment operates in harsh environment.
03. Bearings are replaced frequently to ensure equipment is in operations.
04. Expensive repair and replacement costs.
05. Ensure workforce safety and avoid accidents.
Typical Issues in Cement Plant
- Loosening of nuts, bolts, springs, plates, spring rods, flywheel, bearings, shaft, coupling housing, hammer rotor
- Motor failure, Conveyor belt, Breakage, bearing failure, stretching rod breakage, breakage of separator blade
- Fan bearing breakage, fan unbalance
- Gear knocking, gear tooth wear, gear deformation, gear spitting and spalling
- Disc liner shift
- Rolling mill cracks, tubing failure, pump failure, spoke breakage
- Grate plate breakage
- Axle spindle breakage, crusher bearings failure, slip tape breakage
How can Predictive Maintenance help Cement Plant?
- Vibration reading of equipment can be collected.
- On the basis of real-time triaxial vibrations, a trend can be obtained.
- An insight can be generated which can be considered during weekly or scheduled maintenance work. Further analysis of the insights can speedup decision-making.
- If any abnormality is detected, it can be sent to Maintenance team in the form of SMS and emails.
- A timely remedial measure can be implemented to prevent breakdown, avoid production loss and ensure safety at work.
- Predictive Maintenance can be accordingly scheduled. Corrective measures like Centrifuging, oil top up, oil replacement, bearing/gearbox inspection can be carried.
Predictive Maintenance for Cement plant equipment that’s used for grinding crushing, material transport systems, ball and roller mills, and material separators include:
- Air Compressors
- Belt drives or conveyors
- Fans
- Blowers
- Kiln Rollers
- Motor Bearings
- Vertical and Horizontal Mills
- Hammer Mills
Monitoring vibration energy, acoustics, and temperature helps to understand health condition of equipment.
Case Studies
Cement/Fan
Smart vibration monitoring installed on a critical raw mill fan helped in preventing 50 hours and 44 Thousand USD
Cement/Fan
IDE installed on a critical kiln fan prevented downtime of 144 hours and saved 6.4 Million USD.
Cement/Gearbox
vEdge on a raw mill gearbox helped in preventing unplanned downtime of 50 hours and saved 223 Thousand USD
Cement/Gearbox
IDE vEdge on a raw mill gearbox in a plant of India’s largest cement producer saved 8 hours & 396 Thousand USD
Cement/Fan
Edge computing device on a cooler fan in cement mill saved downtime of 8 hours & 258 Thousand USD
Cement/Bearing
The smart sensor, IDE vEdge monitored critical pinion bearing in cement mill prevented downtime of 16 hours
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