Anoop Anand, Motion System Drives Division President, ABB India, discusses how innovative technologies and solutions help cement plants overcome the challenges related to efficiency.
Tell us about the role of drives in a cement plant machinery.
As an industry, if we evaluate the cost components for making cement, energy cost becomes one of the largest contributors. Due to this, every cement plant closely monitors its energy consumption per tonne of cement production. The quantity of energy consumption is a key deciding factor on whether the manufacturer can be more profitable or competitive in a specific market.
Variable Frequency Drives (VFDs) are commonly used in the cement industry for various applications due to their ability to precisely control the speed of electric motors, thereby optimise the energy consumption in most of the production processes. By adjusting the motor speed to match the required load, VFDs can significantly reduce wastage and improve overall energy efficiency. Like most of the process industries, Cement plants also have various motor-driven equipment, such as crushers, mills, kilns, conveyors, fans and pumps. VFDs provide accurate control of motor speed and torque, enabling efficient operation and better process conditions and process control, and thereby better quality of the product produced. They also allow gradual controlled acceleration and deceleration of motors, reducing mechanical stress and extending equipment lifespan.
Additionally, cement manufacturing processes often involve large motors with high starting currents. VFDs offer soft start capabilities, gradually ramping up the motor speed and reducing the impact of inrush current. This feature not only minimises mechanical and electrical stress on the equipment but also prevents voltage drops in the electrical system during large motor starting.
Conveyors are extensively used in cement plants for transporting materials such as limestone, clay and gypsum. VFDs allow precise control of conveyor speed, enabling optimised material flow and reducing the risk of jams or blockages. When applied to any Fans and Pumps, this enables better control of airflows and fluid flows. VFDs also offer diagnostic features that provide information about motor and system performance, enabling predictive and preventive maintenance practices. They can monitor motor parameters such as temperature, current and vibration, helping identify potential issues before they lead to failures. Overall, VFDs provide significant benefits in terms of energy savings, process control, equipment protection and maintenance in the cement industry. They contribute to improved operational efficiency, reduced downtime and cost saving.
Tell us about the portfolio of drives and motors that you offer to the cement industry.
ABB’s portfolio includes a wide range of low voltage drives, medium voltage drives, DC drives, scalable PLCs, low voltage and medium voltage motors, both Sq Cage and Slip ring and Plant Automation Systems with various process optimisation packages. With our extensive knowledge within cement processing and application, we can offer the right solutions to enhance productivity and energy savings.
With sustainability and enabling a low carbon society now being part of almost all cement manufacturers long term vision, ABB also plays a very positive role in this journey. ABB has targeted to achieve carbon neutrality in our operations by 2030. We also introduced the ‘Energy Efficiency Movement’ globally and many of our customers and even peers in the market are becoming a part of this initiative. In India itself we have about 130+ customers signed up to walk along with us on this journey. We look at sustainability initiatives with a two-pronged approach. One is to support our customers through our products and solutions. Most customers have now moved to High Efficiency motors (IE4) and have also started introducing Ultra Low Harmonic Drives for all their applications. Customers have also been evaluating the long-term benefits of having water cooled solutions for drives and motors as they provide a large potential for energy saving.
The second part of our sustainability journey is implementing actions within our operations which we preach to our customers. I am happy to share with you that when our customers receive our motors and drives, they can be rest assured that they are coming from factories which have most sustainability measures implemented. Our factories are RE100 (renewable energy), water positive, platinum certified green buildings and also working towards zero waste to landfill and single use plastic free operations.
As machinery in cement plants is advancing with time, how do you accommodate the change in drives for the betterment of functionality in cement plants?
ABB Drives have been known for their user friendliness and we also now have all drives covered under the ‘All Compatible’ umbrella where the user conversant with LV Drives from ABB will also have the same look and feel and even operational experience with the interfaces in MV Drives.
The cement industry has been emphasising on digitalisation and ABB is a front runner in developing ways and means to do things better. We now have the option of getting every drive functioning in an industry connected remotely to our remote monitoring centres, which enable 24×7 watch on the critical performance parameters of the drives and proactively advise the plant engineers for taking preventive actions if any negative trend is shown on any critical parameters.
The challenge has always been that it was not economically viable to extend monitoring to a much greater scope of equipment across a plant. That has now changed with the introduction of a new generation of wireless smart sensors for motors. The availability of cloud computing, data analytics, and mobile data transmission, has paved the way for the arrival of low-cost, IoT-based wireless sensors. With no hard wiring requirements, they allow for permanent monitoring at a fraction of the cost of traditional condition monitoring systems.
Tell us about the upcoming innovations from your organisation that would be beneficial for cement plants?
ABB offers a range of innovative solutions that can significantly benefit the cement industry. ABB’s advanced process control systems and optimisation solutions can enhance the efficiency and productivity of cement manufacturing. By leveraging real-time data and advanced algorithms, these systems optimise key process parameters such as kiln operation,
fuel consumption and raw material blending, leading to improved energy efficiency and reduced production costs.
ABB provides robotic solutions for various applications in the cement industry, including material handling, packaging and palletising. These robots can perform repetitive tasks with precision, speed and consistency, reducing manual labour requirements and improving safety in hazardous environments.
Our digital solutions enable the collection, integration, and analysis of data from various sources within the cement plant. By applying artificial intelligence (AI) and machine learning algorithms, these solutions can identify patterns, optimise maintenance schedules, predict equipment failures and improve overall plant performance. Real-time monitoring and remote operation capabilities facilitate proactive decision-making and reduce downtime.
ABB also offers modular and scalable drive solutions that can be customised to meet specific application requirements. This flexibility allows cement manufacturers to adapt their systems to changing needs, expand capacity, and integrate new technologies easily. Our ultra-low harmonic drives help mitigate harmonics and related power quality issues, which in turn also helps in optimising the various equipment in the value chain and save significant energy.
In low voltage motors, we have introduced IE5 efficiency motors using synchronous reluctance technology without the use of permanent magnets. Our innovative designs in HV motors offer high efficiency with high reliability. For example, they have set the world record for HV synchronous motors with 99.05 per cent efficiency.
Our innovation in digitalisation for condition monitoring of LV motors with our smart sensors apart from monitoring critical health parameters also can support in energy appraisal, HV motors monitoring through Machsense-R and remote monitoring of drives helping to predict impending failures and monitor performance.
By leveraging ABB’s innovative technologies, the cement industry can achieve higher levels of operational efficiency, reduce energy consumption, minimise environmental impact, and enhance safety standards. These advancements contribute to the industry’s overall sustainability and competitiveness in an evolving global market.
Which machinery at a cement plant is the most challenging and how do you overcome the challenge?
Among the various machinery in a cement plant, the kiln is often considered one of the most challenging and critical components. The kiln is responsible for the production of clinker, the primary ingredient in cement, through a complex process involving high temperatures and chemical reactions. We have developed innovative solutions to overcome the challenges associated with kiln operations.
ABB’s advanced process control (APC) systems utilise sophisticated algorithms to optimise kiln operations. These systems continuously monitor and adjust critical parameters such as fuel combustion, raw material feed, and air flow to ensure optimal clinker production and energy efficiency. By providing real-time control and optimisation, APC systems enable stable and efficient kiln performance.
ABB’s kiln monitoring solutions incorporate advanced sensors and data analytics to provide real-time insights into the kiln’s condition and performance. Temperature, pressure, and gas composition sensors are deployed to monitor critical areas within the kiln, enabling early detection of anomalies and potential issues. The data collected is analysed using machine learning algorithms to predict and prevent kiln disruptions, optimising maintenance strategies and minimising downtime.
We offers flame monitoring systems that use high-speed cameras and image processing techniques to monitor and optimise the kiln’s combustion process. These systems enable precise control of the flame shape, size, and position, ensuring efficient fuel utilisation and reducing emissions. By continuously analysing the flame characteristics, ABB’s solutions can automatically adjust burner settings to maintain optimal combustion conditions.
Our variable speed drives (VSDs) provide accurate and reliable control of kiln motors, such as those driving the rotating kiln shell and the main drive. VSDs offer precise speed and torque control, enabling smooth and efficient operation, while also reducing mechanical stress on the equipment. ABB’s VSDs also contribute to energy savings by optimising motor performance and reducing power consumption.
ABB’s safety solutions play a crucial role in protecting the kiln and its surrounding infrastructure. Integrated safety systems, including fire and gas detection, emergency shutdown systems, and perimeter monitoring, help prevent accidents and mitigate potential hazards.
By combining these innovative technologies and solutions, ABB helps cement plants overcome the challenges associated with kiln operations. These advancements enable efficient and reliable production of clinker, optimise energy consumption, ensure safety and extend the lifespan of critical kiln components, contributing to the overall performance and profitability of the cement plant.
