Instrumentation, control and electrical systems strategy for a new US cement plant

Many factors must be considered to accomplish a low-cost strategy; site selection, process selection, and equipment selection are a few of the major factors. After these selections are made, the design of the instrumentation and control systems provide a major area of opportunity. The author provides an overview of these systems. The plant of interest is a 1-million-ton-/yr dry process plant consisting of a four-stage precalciner preheater feeding a 14\´6" kiln, and an eight-compartment ventless grate cooler. Issues discussed are process control, process design and control systems, and operator interface. It is concluded that the resulting plant is a low-cost facility with impressive credentials, e.g. heat consumption at 8% below guarantee and power consumption at 95 kW/ST