ONESTONE CONSULTING S.L.

Trends in the performance management
of cement plants

JALINDIA

4 Benchmark 3 Mta Rewa cement plant in India

JALINDIA

Cement Association of Canada

1 Energy efficiency benchmarks

Cement Association of Canada

Holcim

2 Overall performance index (OPI) chart

Holcim

HeidelbergCement

3 Advanced dry pyro-processing at Akcansa in Turkey

HeidelbergCement

Loesche

5 State-of-the-art vertical roller mill (VRM)

Loesche

TKIS

6 State-of-the-art central control room

TKIS

Siemens

7 Condition monitoring of VRM mills

Siemens

TKIS

8 Blending and homogenisation of raw materials

TKIS

OneStone Research

9 Lime standard as a function of material analysis

OneStone Research

FLSmidth

10 Process optimisation with online/inline control loop

FLSmidth

OneStone Research

11 Mixture of different maintenance concepts

OneStone Research

HGH Systems Infrarouges

13 Display of a kiln scanning system

HGH Systems Infrarouges

Italcementi

12 Inspection of a cement grinding plant in Morocco

Italcementi

FLSmidth

14 Financial benefits of O&M outsourcing

FLSmidth

Thyssen Krupp Industrial Solutions

Bearing of a rotary

cement kiln

Thyssen Krupp Industrial Solutions

Benchmarking the performance of cement plants is the trend in the global cement industry and is now widely used. The following article outlines the major implications and focus areas of this approach.

1 Introduction

Cement plants are operating continuously for 24 hours a day and when possible for about 330 days a year without interruption. The rest of the year the plants have their annual shutdown for major repairs. Each day of unscheduled shutdown results in a loss of income, which can be as high as 0.3 million US$ for a standard 1.0 million tons (Mta) capacity plant and cement prices in the range of 100 US$/t. Accordingly plant managers have to concentrate on keeping the plant running and optimising the production costs. These production costs differ greatly depending on region, plant...