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Human -free maintenancd Looking into the future and making predictions is always a difficult task. However, in the cement industry there are some strong trends that could point to future demands and restrictions. By the same token there are dramatic developments in general plant manufacturing and the maintenance industries. Together, these trends plus the advances with lndustry 4.0 can help to have an educated glimpse into the Future of Maintenance or
I
by Dr Gary R Heoth, Costolin Eutectic, Switzerland
lement is used to make concrete,
Figure 1: globaI population and cement demand intensity, 2014-50
L,f,.
most consumed manufactured substance on the ptanet. However, the
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cement sector is the third-largest industriaI energy consumer with a seven per cent share in globaI industrial energy use and
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Figure 2: electrical power demand by process
cement grinding 32o/o
CHINA-production
INDIA- production intensity
O utooir fRsr-
production
intensity
0
(AFs) (see Tabte 1).
Wortd demand intensity
intensity E
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E
-
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cent below current levels by 2050. Four key routes for reducing CO, have been identified, including improving energy efficiency and switching to atternative fuets
Urban population
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Some regions, such as China and
2014 2020 2025 2030 2035 2040 2045
2050
Source: UN DESA, US Geologicol Survey
. less plant staff: mutti-tasking, younger and less experienced with training as key element . maintaining benchmark operational standards in new, remote [ocations . lower spare parts stock.
lmproving energy efficiency will require focus on grinding operation effectiveness and etectricaI power consumption (Figure a
2). From the these trends and is clear
CO2
targets it
that cement plants of the future will
be focussed on CO, reduction, increased use of AFs and improving plant energy efficiency (etectrical and thermal). ln addition, to support these initiatives there witl also be strong financial demands on ptant operation such as: . maximum ptant avaitabitity: no unplanned downtime or waiting for spare parts detivery . longer operationat campaigns and shorter outages . maximum plant operating performance: as designed by plant OEMs
Tabte
l:
lndustry4.0 and the cement industry There is currently much discussion about lndustry 4.0 and how this wil[ revolutionise the industrial wortd and add USSl4trn to the globat economy. Figures
illustrate its background and essentiaI components. Today there are 16bn connected devices, or two devices per person, and
3 and 4
this is expected to doubte by 2020. This impties that cement ptant components
key indicators to achieve targets set by the Gtobal Câ‚Źment lndustry Roadmap
Indicator Electricity intensity of cement (kWh/t cement) Alternative fueI use
ICR JULY2OlB
10000
0
the Middle East, have excess cement production capacity, white others, such as lndia and Africa, willincrease cement production capacity to futfit their infrastructure devetopment needs (see Figure 1). Thus, the cement sectorfaces the challenge of meeting an increasing demand for its product while cutting direct CO, emissions from its production. The gtobat Cement Technotogy Roadmap has an ambitious goatto reduce its direct CO, emissions by 24 per
5
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1600
0,
0l
infrastructure devetopment.
lo/a
Non-urban population
>c
emissions. This cement output, and atong with it, the industry's energy use and CO, emissions, is expected to increase further, driven by an increasing gtobaI poputation, intensifying urbanisation and
FuclgrindinS
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CO-
cement packing and loading
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2000
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2030
2040
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91
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79
5.6
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I DIGITALISATION
lndustry 4.0 - key buzzwords explained
Figure 3: evolution steps to lndustry 4.0
INTERNET OF THTNGS (roT) Globol network of devices ("Things")
thot can identify themselves, be owore of thei r su rround i ngs, com m u nicote directly with eoch other (vio lnternet) ond even oct outonomously.
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E xo BIG DATAANALYTICS DEEP LEARNING
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ARTIFICIAL INTELLIGENCE {AI} Process of collecting, orgonising ond
onalysing lorge sets of dato to discover potterns ond other useful information, typicolly performed using specialised softwore tools, which leorn from doto.
@ Bated onthe tnroductlon
of me(hanic.l produ(ion equipmentdilven by waterand {e.m power
llli|llln[rfti Easedon marrproductlon a(htued bydlvlrlon of labor con(â‚Źptand the u*of ele(nkal enerqy Fhst
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acoustic inputs and processing are common measurements in even low-cost smart phones and accessories.
Maintenance 4.0 in the future The demands placed on the maintenance
displays/aterts have dramaticatly dropped. Location, temperature, motion, vibration,
ele&onr(s and tTto fu(her automrle prdu.tion
Fmfs
and humans could have a similar Level of
for lndustry 4.0 as prices and avaitabitity of key technologies such as sensors, data transfer, data storage, data processing and
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con nectivity.
ln addition, the conditions are right
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of cement ptants today are simitar to those of the past and also of the future:
. maximise ptant availability and cement output . minimise energy consumption and unptanned stoppages
.
reduce frequency/duration of ptanned
maintenance outages . reduce maintenance costs (staff, spare parts, repalrs, etc). However, of particutar relevance today and
fortomorrow are:
.
[imited lifetime of wear parts and reptacement interval not atigned with [onger outage sched u les . new corrosion/wear issues retated to AF use
. monitoring
and predicting when
JULY2OlB ICR
30 YEARS OF
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system to cotlect data using current loT technologies is shown In Figure 6. Such best-practice transfer is a very efficient toot, but IBM recently hightighted the power of its Watson computer with a cement ptant performance optimisation
Figure 4: elements of lndustry 4.0 Mobile Devices lnternet ofThings Cloud computing
case study based on artificiat intetligence Location detection
Augmented reality / wearebles
technologies
Advan(ed human-ma(hine interfa<es
#e Big data analytica
Continuous direct wear monitoring of key components
Authentications & fraud
Smartsensors
(Al). This approach yietded more advances in problem-sotving over the conventionaI experience/ru [e-based approach. This complete plant digital overview also a[[ows for remote operator training with virtuat reality simulation, which wil[ be increasingty required with more comptex operations in remote locations.
dettrtion
3D printing
White vibration monitoring on drives has a tong history, wear sensors are
a
new devetopment. One system being
devetoped involves direct measurement of the type and rate of wear atong with profite changes over time. These can then be tinked to operating conditlon data. Wear sensor technology had a big
Figure 5: targets by globaI cement groups Pdud(aprlly ld.x
potential teap with the commercialisation of 3D cameras in smartphones for profile
mapping (Figure 7).
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Benchmark2ol3
Longer-lasting components of wear parts with a lifetime tailored to plant outage schedules
xxx2013 XXX20I2
XXX = spe(ific Holcim <â&#x201A;Źment plant
Eleculcal En.r9y lndax
As hightighted in Figure 2, increasing the Thermal Energy lndcx
2. Overall performance index
important for cement groups (see Figure 5). This data can atso be used to improve
efficiency of grinding processes is critica[. New process modelling and simulation software can determine an optimal grinding component design. Real-world data is being added to these modets, which inctude casting and surface defects. This can also predict operationalfaiture
equipment design by the OEM. An ideat
regimes to be avoided (see Figure 8).
(oPl) chart Holcim
plant is not running optimally and assessing residua[ lifetimes of key wear components . high cost and long delivery time of replacement parts. With this list of requirements and an understanding of lndustry 4.0, what could the future hotd for the maintenance manager?
Figure 6: sensors, deep learning and communication
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Ptant connectivity and benchmarking to improve local efficiency and design
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Many betieve that lndustry 4.0 wit[ not
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readity apply to cement, but the first steps were atready taken many years
ffi wrywqffimwrH
ago with condition monitoring of critical
motors/drives and deptoyment of gas sensors throughout the plant to batance combustion and emissions. With continuous consotidation in the cement industry, benchmarking a plant's operationaI performance and efficiency is
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However, an important factor wit[ be to
Figure 7: direct measurement of wear in VRM with sensors
ensure a reliabte machine operation that
works at this optimaI design for the majority of its working [ife. Here extending the wear life of the components is key. With a wide range of materlals and realtime wear rate data, the wear life of the component can be taitored to the outage campaigns. Wear is a serious issue as it can atso lead to unplanned downtime. Both are costly consequences in terms of energy, product quality, profit and CO, emissions.
7
Need for advanced wear and corrosion-resistant materials The integration of ceramics and advanced
Weor sensor orroy continuously monitors the VRM weor profile ond iPhone X comero
carbides into metattic-based grinding rollers had a significant impact on the wear life of grinding systems and illustrated the importance of developing novel materials. The next generation of metallic-ceramicpotymer hybrids are currently being tested
with 3D surfoce mo'pping copobility
in the [aboratory. These inctude diamondcontaining composites that have been used successfutty for years in the mining and oiI exptoration industries to extend the lifeti me and mineral fractu ring efficiency. The fatting price of industriatdiamonds and integration of diamond composites into [arge-scale industrial processes could provide solutions for the cement industry
Figure 8: stress modelling of roller press
including materiaI defects Coating system
Material
Coating system
Contact Surface
! !
Roller
1
1
Roller 2
(see Figure 9).
Key component production with 3D
printing and [ocal robot-based repair
Figure 9: diamond-containing wearfacing apptied with industrial processes
With the ever-increasing complexity of components and long detivery times for replacements from the OEM, the abitity to create these components tocatly with 3D printing is appeating. Laser-based 3D metaI part printing and ctadding are showing the most promise. Figure 10 illustrates a comptex-shaped transport screw printed in workshop. A worn ba[[ valve is being repaired automaticalty having already had its wear profile 3D scanned, With the reduction in the price of robots a smatt
201AtO5D5
H
MUD'13.0
x30
2 mm
Figure 10: laser 3D coating and printing of wear components
and laser systems construction, local repair and coating of criticaI wear and corrosion components is now possibte, and on-site laser cladding is a proven technology in other industries.
Conclusions The etements of wear monitoring, newwear and corrosion-resistant materials, advanced wear modetting and new
maintenance technologies wi[[ ptay a cruciaI role in achieving future cement industry goats while wholeheartedty embracing the Maintenance 4.0 phitosophy.
I JULY 2018