Siemens CEMAT: Process Control for the cement industry

SIEMENS CEMAT is an enhancement of the SIMATIC PCS 7 process control system thatImage result for siemens cemat was designed for the special requirements in the cement and mining industry and has proved successful in many years of use worldwide in the tough environmental conditions of cement works.

The current system platform for Siemens CEMAT is the SIMATIC PCS 7 process control system whose modern architecture offers the ideal basis for future-proof and economical solutions. Siemens CEMAT utilizes the basic functionality, open system interfaces, flexibility and scalability of SIMATIC PCS 7 and optimizes the operating philosophy as well as the diagnostic, signaling and interlocking concept with industry-specific software for the requirements in lime and cement works as well as in mining. This industry software was developed in close collaboration with cement manufacturers and mine operators and is the product of over 40 years of experience in the cement industry.

CEMAT based on SIMATIC PCS 7

CEMAT based on SIMATIC PCS 7

CEMAT breaks new ground in every way, and offers new opportunities in cement production because its technology basis is SIMATIC PCS 7. And since it delivers the highest levels of reliability across all industries, the standardized hardware and software of this world leading process control system stand out from the competition. The CEMAT system includes all necessary components and is perfectly tailored to meet the demands of the cement industry.

Optimized processes

Optimized processes for the cement production industry

The CEMAT process control system offers the best way to optimize cement production potential – at all corporate levels and throughout the value chain. CEMAT helps reduce cement production costs through resource management and productivity monitoring – from raw materials to finished products. With just a few mouse clicks, the operator has access to all relevant production data e.g. status of running machines, fault and alarm, maintenance etc., in order to run the production in the most efficient way. As a result, CEMAT makes a significant contribution to optimizing cement production capacities facility-wide.

Additional CEMAT benefits for the cement industry include excellent operation and integrated diagnostic features, which help detect potential faults quickly – before a problem – and minimize outages.

Kiln Control System

Kiln Control System (KCS)

kcs

The cement manufacturing process is a highly energy-intensive process, with many unpredictable disturbances. To manage process, the operators are spending a lot of time, efforts and have to permanently monitor the process very carefully. The goal of the Kiln Control System is to increase the quality as well as efficiency of clinker production. KCS ensures varying reactions exactly adapted to the actual process condition so that the plant is run with “best practice” – control operations – as soft as possible and at the same time as effective as required.

Mill Control System

Mill Control System (MCS)

Cement milling is in particular a highly energy-intensive process, there are potential energy savings available through the use of Mill Control System. The MCS is a software system that draws conclusions about the quality levels of the production plant through a knowledge-based approach using current plant data (defined measured values). The process optimization system MCS delivers continuous values for this quality parameter that can otherwise only be determined by a laboratory system at specific intervals.

Management Information System

Management Information System (MIS)

Management Information System for CEMAT archives the data and alarms received from the process control systems and provide these for analyses and evaluations. With the historical data display (HDD) the user is able to assort the desired curve charts. He can look at current data and at data from the past. He also has the possibility to compare plant behaviors with each other using trend charts at different times. The consistent data management enables seamless control of all production and business processes.

Process Instrumentation and Control

Process Instrumentation and Control

During cement manufacture it is necessary to closely measure all output values. SICEMENT Instrumentation is a completely integrated product range for obtaining the most accurate results in process measuring technology.

SIEMENS CEMAT FUNCTION

Function

Example of a cement mill with Siemens CEMAT functionality SPC (Scalable Production Control) for easy recipe and material management

The functionality for the cement and mining industry supplied by Siemens  CEMAT is integrated into the system structure of SIMATIC PCS 7 during installation, and can be classified as follows:

  • Software blocks for automation tasks typical at customers in the cement and mining industry
  • Modules for controlling motors, valves, and flaps and for processing of analog and binary signals
  • Modules for structuring and simplified operation of the plant in groups and paths
  • Scalable Production Control (SPC) for recipe-based control strategies
  • HMI components with:
    • Library for all control system objects with information, diagnostic, and multimedia dialogs
    • Message system with industry-specific service functions
    • Diagnostic system for fast recognition of faults and reduction of downtimes
    • Additional functions such as signal tracking and signal status information
    • APL-style design
  • Web-compatible visualization of process displays and faceplates
  • Management information: listing and statistics functions as well as long-term archiving
  • Maintenance function with:
    • Definition of maintenance intervals for analog and binary modules
    • Recording of maintenance actions