Technology
Towards a smart world
Published
8 years agoon
By
admin
IT has been making radical changes in how we do things, and the cement industry is no exception. Condition monitoring of high-value assets is an age old practice, but the novelty brought in by IT, is on line condition monitoring even from remote places. DALOG from Germany has taken pioneering steps to propagate the idea.
To prevent breakdowns is good but the goal must be to avoid machine failures from the beginning. This has been the aim of the DALOG GmbH for almost two decades. Ever since their online condition monitoring systems helped to maximise the availability of machines by making precise analysis and supporting the plant team remotely with failure predictions, maintenance preparation support, and even advice for process improvement. Yet, the outcome on the production can only be assured by an interconnected monitoring solution that covers the full value chain of the cement production process.
Process correlated condition monitoring
Creating save islands in the plants by monitoring the most critical assets with acceleration and temperature sensors allows to predict failures on gears and bearings before they end in a catastrophic breakdown. A tooth failure on a gear can be detected before it breaks off and turns into a loose cannon within the gearbox. A bearing with upcoming pitting can be ordered in time. Statistical models even allow to predict the remaining lifetime of a machine component. In general, failures are detected at an early stage, which gives time to act and plan. Plants benefit from less unplanned stoppages and a minimisation of secondary damages.
The next logical goal is to increase the time between failures, by optimising operational stability. The torque measurement on rotating shafts has shown to precisely measure the real load on the machine and a high frequency measurement shows peaks not visible in the motor power. Consequently, it is a valuable tool to evaluate operational stability and to detect dangerous overloads on the machine. This is especially important for machines with a high dynamic process like vertical roller mills and roller presses, where operational instability can often be related to issues in the grinding elements or the process, like an improper feed. For a root cause analysis in the process, the online condition monitoring system needs to be able to communicate with the PLC to receive parameters like feed rate, pressures and motor power; sending alarms and trends to the DCS, helps to integrate the operators in the project, which gives them the necessary information to take appropriate measures to prevent machine failures or instabilities.
One of the big challenges for the cement industry towards a successful transition to the digital factory, will be the standardisation of communication protocols. OEM proprietary protocols dominate the cement plants and given that this situation will not change soon, the DALOG condition monitoring system supports most of the fieldbus protocols, to establish a bi-directional communication with the PLC. The key elements to prevent failure in the future are real load measurements with a torque sensor, the data exchange (process and condition) between the condition monitoring system and machine control, and the integration to the operator.
Online data acquisition for all machines
The industry has made great progress in the last years with its maintenance strategies. The FMEA (Failure Mode and Effects Analysis) today is a standard tool evaluate risks and thus even today many of the most critical machines, like mills and kilns, are equipped with an online condition monitoring system and respectively covered by the predictive maintenance strategy. Nevertheless, less complex and smaller equipment, like fans, conveyors, or bucket elevators, often fall through the net, besides its clear impact on the production. The maintenance strategy for those machines in today`s plants are either "run to breakdown", preventive, or condition based with temporal measurements on the equipment. They all have in common that the initial investment is very low, but the ongoing operational costs are soaring. The run to failure strategy bears a lot of risks and will cause unplanned stoppages and production loss.
Preventive maintenance reduces the risk, but relies solely on life-time estimations or manual inspections to schedule maintenance intervals. This either results in changing machine parts too early or too late, one ends in higher spare part investment, the other in production loss. Condition based maintenance intervals can be achieved by mobile measurements. Yet, the quality and reliability of an analysis with mobile equipment has a high variance. They are time consuming and must be carried out by trained personal that needs to fulfill a rigid schedule taking those measurements. Risks involve selecting a non-optimal measurement position, not considering different machine production situations at the time of the reading, or in the worst case, not taking the measurement after all. Trend analysis and process correlation is in the best case suboptimal.
The cement plant of the future will solely rely on a predictive and proactive maintenance strategy, which bases its decisions on data from online condition monitoring systems. The advantage lies on the hand: while reducing time consuming field work, the plant can count on more precise measurements and a higher data density, thus a higher reliability of their predictions and consequently a higher availability of the plant.
New challenges for maintenance
As the data density increases and analysis algorithms improve, what about the typical tasks for the maintenance team? While it is possible to measure the impacts of the tropical rain fall on the feed of a vertical roller mill in a cement plant in the Philippines, or to detect the effects of sand (silica) on the operational stability in a roller press in the Mid-West, it is yet a great task to integrate all the external influences into an algorithm that could replace the judgement of a trained expert. On the other hand, as reliability increases and field work decreases, more time and effort will be spent on performance optimisation and the collected data will build the foundation to plan, carry out and measure the outcomes of such initiatives. Experienced vibration analysis, maintenance, and process experts from DALOG, guide already today many plants to interpret the data and optimise their performance.
Online condition monitoring
How can online condition monitoring go even further and support a company-wide strategy? Wikipedia defines strategy as "a high-level plan to achieve one or more goals under conditions of uncertainty". It is clear how online condition monitoring continuously provides information to maintenance to eliminate uncertainty. But why stop there? The DALOG online condition monitoring solution acquires data in high resolution to evaluate machine condition, operational stability and process parameters that will help to evaluate the overall performance. The latest software generation DALOG Busy Bee calculates KPIs and statistics that are visualised in customisable dashboards. It is possible to display statistics about machine availability, energy consumption and operational stability, to name just a few. Surely, the access to the data is not limited locally to plant facilities. An encrypted connection to the cloud permits to access the data worldwide from a laptop, smartphone or tablet. This allows regional managers and headquarters to gain insight about the performance and condition of cement plants of a region, or country, thus any production strategy within the organisation will be exposed to less uncertainty.
A look back and the possibilities we have today
DALOG was founded in 1998. Back then, it was state-of-the-art to equip the monitoring system with a GSM module to dial up and establish a 9.6 kBit/s connection. Few people back then could have imagined that today most plants have access to the internet 1,00,000 times faster (1 Gbit/s). I would not dare to make a prediction for the technology we will have in 20 years, but I can say what is possible since today.
The DALOG Plant Protection Concept is a bottom up approach where on the lowest layer data is collected and stored on the cloud.
The massive amount of data is processed to be useful for different stakeholders within the same organisation. The maintenance team can work with precise failure analyses and can plan maintenance intervals based on machine condition and proactively work on increasing the time between machine failures.
The production team gains statistics and models for production planning. The plant manager can evaluate overall plant performance comfortably from his smartphone. In the end, online condition monitoring will build the foundation, for a seamless integration of data-driven decision making within the whole organisation.
Courtesy: DALOG, Diagnosesysteme GmbH, Muehlbachstr. 21
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We consistently push the boundaries of technology
Published
2 months agoon
April 18, 2025By
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Swapnil Jadhav, Director, SIDSA Environmental, discusses transforming waste into valuable resources through cutting-edge technology and innovative process solutions.
SIDSA Environmental brings decades of experience and expertise to the important niche of waste treatment and process technologies. As a global leader that is at the forefront of sustainable waste management, the company excels in recycling, waste-to-energy solutions and alternative fuel production. In this conversation, Swapnil Jadhav, Director, SIDSA Environmental, shares insights into their advanced shredding technology, its role in RDF production for the cement industry and emerging trends in waste-to-energy solutions.
Can you give us an overview of SIDSA Environmental’s role in waste treatment and process technologies?
SIDSA is a leading innovator in the field of waste treatment and process technologies, dedicated to delivering sustainable solutions that address the growing challenges of waste management.
SIDSA is a more than 52-year-old organisation with worldwide presence and has successfully realised over 1100 projects.
Our expertise is in the engineering and development of cutting-edge systems that enable the conversion of waste materials into valuable resources. This includes recycling technologies, waste-to-energy (W2E) systems, and advanced methods for producing alternative fuels such as refuse derived fuel (RDF). The organisation prioritises environmental stewardship by integrating energy-efficient processes and technologies, supporting industrial sectors—including the cement industry—in reducing their carbon footprint. Through our comprehensive approach, we aim to promote a circular economy where waste is no longer a burden but a resource to be harnessed.
How does SIDSA Environmental’s shredding technology contribute to the cement industry, especially in the production of RDF?
SIDSA’s shredding technology is pivotal in transforming diverse waste streams into high-quality RDF. Cement kilns require fuel with specific calorific values and uniform composition to ensure efficient combustion and operational stability, and this is where our shredding systems excel. In India, we are segment leaders with more than 30 projects including over 50 equipment of varied capacity successfully realised. Some of the solutions were supplied as complete turnkey plants for high capacity AFR processing. Our esteemed client list comprises reputed cement manufacturers and chemical industries. Our technology processes various types of waste—such as plastics, textiles and industrial residues—breaking them down into consistent particles suitable for energy recovery.
Key features include:
- High efficiency: Ensures optimal throughput for large volumes of waste.
- Adaptability: Handles mixed and heterogeneous waste streams, including contaminated or complex materials.
- Reliability: Reduces the likelihood of operational disruptions in RDF production. By standardising RDF properties, our shredding technology enables cement plants to achieve greater energy efficiency while adhering to environmental regulations.
What are the key benefits of using alternative fuels like RDF in cement kilns?
The adoption of RDF and other alternative fuels offers significant advantages across environmental, economic and social dimensions:
- Environmental benefits: Cement kilns using RDF emit fewer greenhouse gases compared to those reliant on fossil fuels like coal or petroleum coke. RDF also helps mitigate the issue of overflowing landfills by diverting waste toward energy recovery.
- Economic savings: Alternative fuels are often more cost-effective than traditional energy sources, allowing cement plants to reduce operational expenses.
- Sustainability and resource efficiency: RDF facilitates the circular economy by repurposing waste materials into energy, conserving finite natural resources.
- Operational flexibility: Cement kilns designed to use RDF can seamlessly switch between different fuel types, enhancing adaptability to market conditions.
What innovations have been introduced in waste-to-energy (W2E) and recycling solutions?
SIDSA’s machinery is meticulously engineered to handle the complex requirements of processing hazardous and bulky waste.
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- Robust construction: Our equipment is designed to manage heavy loads and challenging waste streams, such as industrial debris, tires and large furniture.
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How does your organisation customised solutions help cement plants improve sustainability and efficiency?
We consistently push the boundaries of technology to enhance waste management outcomes.
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- Energy-efficient shredders: These machines consume less power while maintaining high throughput, contributing to lower operational costs.
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- Advanced gasification technologies: Convert waste into syngas (a clean energy source) while minimising emissions and residue.
- Closed-loop recycling solutions: Enable the extraction and repurposing of materials from waste streams, maximising resource use while reducing environmental impact.
What future trends do you foresee in waste management and alternative fuel usage in the cement sector?
Looking ahead, several trends are likely to shape the future of waste management and alternative fuels in the cement industry:
- AI integration: AI-driven technologies will enhance waste sorting and optimise RDF production, enabling greater efficiency.
- Bio-based fuels: Increased use of biofuels derived from organic waste as a renewable and low-carbon energy source.
- Collaborative approaches: Strengthened partnerships between governments, private industries and technology providers will facilitate large-scale implementation of sustainable practices.
- Circular economy expansion: The cement sector will increasingly adopt closed-loop systems, reducing waste and maximising resource reuse.
- Regulatory evolution: More stringent environmental laws and incentives for using alternative fuels will accelerate the transition toward sustainable energy solutions.
(Communication by the management of the company)
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Decarbonisation is a focus for our R&D effort
Published
4 months agoon
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Dyanesh Wanjale, Managing Director, Gebr. Pfeiffer discusses the need to innovate grinding technologies to make the manufacturing process more efficient and less fuel consuming.
Gebr. Pfeiffer stands at the forefront of grinding technology, delivering energy-efficient and customised solutions for cement manufacturers worldwide. From pioneering vertical roller mills to integrating AI-driven optimisation, the company is committed to enhancing efficiency and sustainability. In this interview, we explore how their cutting-edge technology is shaping the future of cement production.
Can you tell us about the grinding technology your company offers and its role in the cement industry?
We are pioneers in grinding technology, with our company being based in Germany and having a rich history of over 160 years, a milestone we will celebrate in 2024. We are widely recognised as one of the most efficient grinding technology suppliers globally. Our MBR mills are designed with energy efficiency at their core, and for the past five years, we have been focused on continuous improvements in power consumption and reducing the CO2 footprint. Innovation is an ongoing process for us, as we strive to enhance efficiency while supporting the cement industry’s sustainability goals. Our technology plays a critical role in helping manufacturers reduce their environmental impact while improving productivity.
The use of alternative fuels and raw materials (AFR) is an ever-evolving area in cement production. How does your technology adapt to these changes?
Our vertical roller mills are specifically designed to adapt to the use of alternative fuels and raw materials. These mills are energy-efficient, which is a key advantage when working with AFR since alternative fuels often generate less energy. By consuming less power, our technology helps bridge this gap effectively. Our solutions ensure that the use of AFR does not compromise the operational efficiency or productivity of cement plants. This adaptability positions our technology as a vital asset in the industry’s journey toward sustainability.
What are some of the challenges your company faces, both in the Indian and global cement industries?
One of the major challenges we face is the demand for expedited deliveries. While customers often take time to decide on placing orders, once the decision is made, they expect quick deliveries. However, our industry deals with heavy and highly customised machinery that cannot be produced off the shelf. Each piece of equipment is made-to-order based on the client’s unique requirements, which inherently requires time for manufacturing.
Another significant challenge comes from competition with Chinese suppliers. While the Indian cement industry traditionally favoured our technology over Chinese alternatives, a few customers have started exploring Chinese vertical roller mills. This is concerning because our German technology offers unmatched quality and longevity. For example, our mills are designed to last over 30 years, providing a long-term solution for customers. In contrast, Chinese equipment often does not offer the same durability or reliability. Despite the cost pressures, we firmly believe that our technology provides superior value in the long run.
You mentioned that your machinery is made-to-order. Can you elaborate on how you customise equipment to meet the specific requirements of different cement plants?
Absolutely. Every piece of machinery we produce is tailored to the specific needs of the customer. While we have standard mill sizes to cater to different capacity requirements, the components and configurations are customised based on the client’s operational parameters and budget. This process ensures that our solutions deliver optimal performance and cost efficiency. Since these are heavy and expensive items, maintaining an inventory of pre-made equipment is neither practical nor economical. By adopting a made-to-order approach, we ensure that our customers receive machinery that precisely meets their needs.
The cement industry is focusing not only on increasing production but also on decarbonising operations. How does your company contribute to this dual objective, and how do you see this evolving in the future?
Decarbonisation is a key focus for our research and development efforts. We are continuously working on innovative solutions to reduce CO2 emissions and improve overall sustainability. For example, we have significantly reduced water consumption in our processes, which was previously used extensively for stabilisation. Additionally, we are leveraging artificial intelligence to optimise mill operations. AI enables us to monitor the process in real-time, analyse feedback, and make adjustments to achieve optimal results within the given parameters.
Our commitment to innovation ensures that we are not only helping the industry decarbonise but also making operations more efficient. As the cement industry moves toward stricter sustainability goals, we are confident that our technology will play a pivotal role in achieving them.
Can you provide more details about the use of digitalisation and artificial intelligence in your processes? How does this improve your operations and benefit your customers?
Digitalisation and AI are integral to our operations, enabling us to offer advanced monitoring and optimisation solutions. We have developed three distinct models that allow customers to monitor mill performance through their computer systems. Additionally, our technology enables real-time feedback from our German headquarters to the customer. This feedback highlights any inefficiencies, such as when a parameter is outside the optimal range,
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By continuously monitoring every parameter in real time, our AI-driven systems ensure that mills operate at peak efficiency. This not only enhances production but also minimises downtime. I am proud to say that our mills have the lowest shutdown rates compared to other manufacturers. This reliability, combined with the insights provided by our digital solutions, ensures that customers achieve consistent and efficient operations. It’s a game-changer for reducing costs and enhancing overall productivity.

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