17 minute read
Welcome
Next Article
WELCOME WELCOME
LOCAL CONFERENCE COMMITTEE
Local Chair
Mark Mueller
Vice Chair
Anya Gill
Secretary
Jennifer Flemming
Conference Liaison
Jeff Nagel
Advisors
Thomas Turano Brett Lindsay John Kline
Promotion/Publicity
Tina McIntyre
Publications
Scott Zolotsky
Plant Liaison
Robert Shenk Marco Vannucchi
Sponsorships
Suhail Akhtar
MARK MUELLER, 2021 ORGANISING CHAIR
Hello all – I would like to formally invite you to join us for the 63rd Annual IEEE-IAS/PCA Cement Industry Technical Conference. As we all know, the 2020 Las Vegas Conference was cancelled based upon an abundance of caution during the Covid-19 pandemic and the 2021 Conference, after much deliberation, will be held virtually on The Aggregate platform.
Based upon one of the most engaging 3D platforms available to us, we will embark on a very familiar and realistic conference experience, much like what we have known for decades except with our own avatars. The feel of the conference will be very similar to the past, the information exchange is nearly identical, as is the ability to catch up with old friends and colleagues.
There are some distinct benefi ts to this conference format. With your avatar, you can navigate at a click of a button to get to a presentation, exhibit hall, or meet up with attendees without losing time searching. And we will be able to bring the world to the conference in ways we haven’t been able to before. Not only will attendees from around the world be able to easily attend, but we are also featuring multiple plant tours including locations that would not easily host a conference of our size.
For 2021 we have formatted the conference to begin Tuesday 25 May, and close in the afternoon of Thursday 27 May with training continuing through the afternoon of Friday 28 May. Furthermore, we have all of the content that makes this conference so valuable, being held between 10 am EST and 4:30 pm EST. The schedule includes: 20+ Technical papers/presentations with Q&As Keynote speakers 2021 PCA economic forecast 2.0 level process training MSHA refresher training Exhibit hall Spouse programme Worldwide plant tours
So please, come visit us at www.cementconference.org to review the Technical Content, Exhibitor Information and Registration pages to see what we have to offer. And please note that our registration costs are much lower this year, with no need for travel, hotel rooms and time away from the offi ce. This will be a memorable experience.
I would like to take a moment to thank all of the volunteers who are working tirelessly to organise this year’s conference. The Executive Committee of the CIC, all of the Working Groups and the PCA Staff who submit, vet and approve all of the technical content and to the 2021 Local Committee who have been working for over a year on organising the conference. Without all of their support, this conference would not be possible. Thank you, all!
Lastly, it is not without some sadness that we all remember those who have been tragically impacted by the Covid-19 pandemic, and to them, our thoughts and prayers are with you.
The IEEE-IAS Cement Industry Committee introduces the highlights of this year’s IEEE-IAS/PCA Cement Industry Conference programme.
GOING GOING VIRTUAL VIRTUAL
Welcome to the 63rd Annual elcome to the 63rd Annual research and thoughts on topics that affect cement research and thoughts on topics that affect cement IEEE-IAS/PCA Cement Industry IEEE-IAS/PCA Cement Industry manufacturing. Additionally, a panel discussion manufacturing. Additionally, a panel discussion Technical Conference. This year’s Technical Conference. This year’s on environmental topics affecting our industry on environmental topics affecting our industry conference is being held virtually conference is being held virtually allows attendees access to multiple perspectives allows attendees access to multiple perspectives in the Aggregate 3-D platform and is sure to be a in the Aggregate 3-D platform and is sure to be a on topics ranging from fuels and raw materials to on topics ranging from fuels and raw materials to memorable event, and one not to be missed! Here memorable event, and one not to be missed! Here cap and trade issues. A series of process training cap and trade issues. A series of process training is a preview of what to expect: is a preview of what to expect: sessions (PT 2.0) will be available to conference sessions (PT 2.0) will be available to conference
As in years past, the heart of the conference As in years past, the heart of the conference registrants, Monday to Friday, to gain additional registrants, Monday to Friday, to gain additional is the technical papers and panel discussions, is the technical papers and panel discussions, experience and professional development within experience and professional development within which will take place during the General Session, which will take place during the General Session, the cement industry. A unique feature to this year’s the cement industry. A unique feature to this year’s Tuesday 25 May through Thursday 27 May. The Tuesday 25 May through Thursday 27 May. The conference is the inclusion of multiple cement conference is the inclusion of multiple cement 26 technical papers this year are a product of 26 technical papers this year are a product of plant tours, including unprecedented access to plant tours, including unprecedented access to hard work from authors looking to provide their hard work from authors looking to provide their international cement plants. international cement plants.
Tuesday’s General Session kicks off as Rick Bohan, PCA Vice President of Sustainability, keynotes this year’s conference with an update on the cement industry’s roadmap to carbon neutrality. Rick will highlight the approach that the PCA-led effort will take to achieve carbon neutrality by 2050. Highlights of the presentation include leveraging the entire value chain: from clinker to cement to concrete to construction to using concrete as a carbon sink. He will show how small changes at the upstream end of the value chain create big impacts in downstream carbon intensity at the concrete and construction stages. The presentation will include roadmap aspects on CCUS, transformational fuels, and carbonation models. This is a must attend event for anyone serious about the critical role cement and concrete have in sustainability and addressing climate change. The technical papers will then make up most of the remainder of the day before closing with plant tours and Q&As.
Wednesday’s schedule begins with a Portland Cement Association (PCA) update given by its CEO, Mike Ireland. Following the update, Ed Sullivan, Senior Vice President and Chief Economist of the PCA, will again present his State of the Industry update. Ed is always a favourite of conference attendees and we look forward to hearing his economic outlook. Wednesday’s session then heads into technical paper presentations and wraps up with plant tours and question and answer sessions.
Thursday’s schedule is a full day of technical papers and the remaining cement plant tours, culminating with Technical Paper Awards and closing comments.
Technical programme highlights:
Technical papers and panel discussions
Automation Working Group Applying Unmanned Aerial Vehicle (UAV)
Technology in the Cement and Mining
Industries » Author: Adam Chapman PGNAA Cement Analyzer Optimization » Authors: April Montera & Paul Iverson Implementation of Artifi cial Intelligence
Technology to Optimize Clinker Coolers » Authors: Roberto Linares, Ph.D. & Prabal Acharyya Advanced Analytics for Cement Manufacturing » Authors: Jairo Gomez & Brian Crandall
Drives & Related Products Working Group Fan Bearing Varieties and Thermal Analysis » Author: Matt Zwick Using Condition Monitoring Tools to Improve the Reliability of Various Hydraulic Drive
Systems for Cement Plant Applications » Author: Ashok Amin Study of Heat-Load Management of Medium
Voltage Variable Frequency Drives » Author: Navid Binesh A Simplifi ed Calculation for Motor Starting Time » Author: Gary Bankay
Environmental, Energy & Sustainability Alternative Raw Materials and Impacts on the
Cement Manufacturing Process and Regulated
Air Emissions » Authors: Branden Barry, Ron Hawks, Mark Junkins & Luis Rodriguez Pathways to Alternative Power and
Decarbonization Technologies in Cement
Manufacturing » Authors: Gerald Ayling P.E., Ashrith Domun, E.I.T. & Gino de Villa Top Inlet Vacuum Shock Baghouse Technology
Reinventing Baghouses for Improved
Performance and Simplifi ed Maintenance » Author: Luis J. Castaño An Empirical Examination of the Carbonation of
Concrete at a California Site » Authors: George Hartman, Jr., Steven Regis & Hartmut Riess Improving Cooling Performance of Gas
Conditioning Towers/Downcomers to Reduce
Plant Emissions » Authors: Robert VanDurme, P.E., Marek Serafi n & Stewart McKenzie Use of Next Generation Emission Measurement
Sensors and Data Analysis in Industrial
Applications » Authors: Ali Lashgari & Volker Schmid Panel Discussion: Environmental Overview:
From Fuels and Raw Materials to Cap and
Trade » Authors: Pedro Maiz, Frederick DeRaedt, Sean O’Neill & Steve Walters
General Practices Working Group Fully Automated Cement Horizontal Storage (FACHS) A New Concept to Store Cement » Authors: Desi Delgado & Luis Sucre Structural Failures & Collapses in Cement
Plant Facilities » Authors: Guillermo Etse, Veronica Buncuga & Andres Danert Five Months to New Ball Mill Installation
Delivers Two Extra Weeks of Production » Authors: John, Dale, Manuel Sanchez, Ronald Nikoleyczik & Jose Venegas Implementation of Studded Roll Bodies For
Raw Material HPGR Grinding System
» Authors: Samira Rashidi, Stefan Diedenhofen & Alan Simmons Balancing Kiln and Calciner Operation – A
Case Study » Authors: Syed Suhail Akhtar, Tahir Abbas & Paul Rogers Boosting Runtime and Production Factors with Reliability Centered Maintenance » Authors: Scott Hall, Jose Gil & Omar Vizcarra
Power Generation, Distribution and Related Products Working Group Consideration of Standards and
Recommendations for Selection, Installation, and Maintenance of Substation Transformers » Authors: David B. Durocher, Marc C. Elliott & Sam Reed Emerging Applications for IEC 61850 in Process Industry Power Distribution
Systems » Authors: Matthew P. Ellis, P.E., Vignesh Palanichamy & Navin Shanoy Benefi ts of Micro-grids/Energy Storage for the Cement & Mineral Industries: Part II. The
Green Hydrogen Option » Authors: Xavier d’Hubert, Francois Henry & Stephane Poellaer A Guide for Enhancing Existing Plant
Electrical Consumption Monitoring System » Author: Tim Noss Applying Line-Side Isolation to Enhance
Arc-fl ash and Shock Protection in
Low-Voltage Power Distribution Equipment » Authors: Tim Faber & Anthony Parsons
Maintenance & Safety Working Group Lubrication Best Practices » Author: John Kline Outage Planning for Silo Inspection and
Repairs » Author: Gerry Lynskey, S.E., P.E., P.Eng
Process training
Process training will take place on each day Monday through Friday, covering a variety of topics from emissions handling to energy management best practices. A PCA roundtable will highlight each day’s topics.
Monday 24 May The Optimization of Reagents for Controlling
SO2, HCl, and Hg Emissions » The usage of sorbents (such as lime injection and activated carbon) strongly impacts plant operational costs. This training module will present ‘reality checks’ on sorbent usage by looking
ELEVATE. DON’T CLIMB.
ARE YOU PAYING SKILLED STAFF TO CLIMB STAIRS OR TO PRODUCE CEMENT?
DON’T CLIMB. ELEVATE.
Cement plants all over the world rely on Alimak rack and pinion elevators to provide reliable, efficient vertical access for maintenance and inspection. Designed to operate in demanding industrial environments, outdoors and indoors, Alimak elevators require no expensive shafts or machine rooms, and they can easily be installed on new and existing structures. Standard capacities range from 300 kg to 7,000 kg, with up to 24-ton capacity available upon request.
at the means & methods to reduce overall usage of such costly reagents for optimal effectiveness. » Developed and presented by Peter Paone of Bridge Gap Engineering. PCA Roundtable: The Hidden Costs of
Overburning Your Clinker » Presented by Rick Bohan & John Kline. Successful Energy Management » This training module will explore key factors in the implementation of a successful energy management programme –including Energy Star Certifi cation » Developed and presented by William Jerald –Calportland Cement Company. Process Evaluation of Vertical Mill Systems » This training module will identify the key process variables that inform process engineers and production managers whether their mill systems are operating at or near peak performance by using tools to diagnose their mill system’s performance. » Developed and presented by David Fortsch of Bridge Gap Engineering.
Tuesday 25 May The Optimization of Reagents for Controlling
NOx Emissions » The usage of ammonia and urea strongly impact plant operational costs. This training module will present ‘reality checks’ on the amounts of reagent usage by looking at the means & methods to reduce overall usage of costly reagents for optimal effectiveness. » Developed and presented by Peter Paone of Bridge Gap Engineering. PCA Roundtable: How to Read Your Cement
Mill Test Report » Presented by Rick Bohan & David Fortsch. Successful Alarm Management » What good are process control alarms if they are so frequent that they are continuously silenced by control room operators? This training module will present a strategic approach for the implementation of a quality alarm management system based on the ISA Standard 18.2. » Developed and presented by John Kline of Kline Consulting. Process Control Strategies » This training module will present recommended control strategies for the successful operation of all major pieces of equipment in a cement plant. The training module will present expert opinion and experiences with control loops that do & don’t work well. » Developed and presented by John Kline of Kline Consulting. Wednesday 26 May Handy Emissions Calculations & Conversions » This training module will enable participants to understand the basic units of measure for environmental emissions measurements. It will educate participants on how to quickly convert between ‘measured values’ in ‘ppm’, for example, to ‘permit values’ such as ‘lb/ST clinker’ or ‘mg/m3, dry basis at 7% O2’, for example. » Developed and presented by Peter Paone of Bridge Gap Engineering. PCA Roundtable: The Hidden Costs of
Inconsistent Kiln Feed Chemistry » Presented by Rick Bohan & Peter Paone. Successful Process Control Strategies » This training module will present control loop experiences for the successful operation of all major pieces of equipment in a cement plant. Expert opinion and experiences with control loops will be offered. » Developed and presented by John Kline of Kline Consulting. Kiln Burner Momentum Calculation and Control » The objectives of this training module are to learn to calculate burner momentum, to understand the effect of fuel transport air on burner momentum, and to study the recommended momentum values for fi ring various types of fuels. » Developed and presented by Jean Jung of Fives-Pillard.
Thursday 27 May Preheater Tower Build-Ups, Kiln Balls & Rings, and Cooler Snowman » This training module will explore various types of build-ups and ring formations that are found in pyroprocessing systems. Cause & effect relationships will be explored as well as recommended mitigation strategies. » Developed and presented by Peter Paone of Bridge Gap Engineering. PCA Roundtable: How Best to Achieve
Consistency of Your Cement Products » Presented by Rick Bohan & Kimberly Gordon. Leading Cement Terminal Technology » Did you know there are more than 500 cement terminals in the US and Canada? This training module will explore the various technologies available and implemented at cement terminals from the smallest rail terminals to the largest barge terminals. » Developed and presented by John Kline of Kline Consulting. Cement Imports and Import Terminals
» This training module will explore the various technologies available for import terminals. The current and future status of cement ocean/import terminals will be reviewed. » Developed and presented by John Kline of
Kline Consulting.
Friday 28 May Production Levers » This training module will examine the production optimization process and improving operational effi ciencies which are often at odds with maximum production. » Developed and presented by John Kline of Kline Consulting. PCA Roundtable: Summary of the Week’s
Discussions » Presented by Rick Bohan. An Assessment of Your Plant’s Lubrication
Practices » This self-assessment will examine your plant’s practices for its lubrication systems and rank these practices from ‘Poor’ to ‘Mastery’. » Moderated by John Kline of Kline Consulting. Lubrication Best Practices » This training module will explore best practices for lubrication systems. Lubrication is the lifeblood of the equipment in the plant. Improving lubrication practices will improve uptime and reduce maintenance costs. » Developed and presented by John Kline of Kline Consulting.
Exhibit hall
Don’t forget to take a walk through this year’s Exhibit Hall while you are attending the conference. The conference provides a valuable opportunity for the over 100 vendors and suppliers to network with cement producers. The Exhibit Hall opens Tuesday morning at 10am EST. Exhibit hours are from 10am – 2pm EST, 25 – 27 May. These hours will provide attendees the opportunity to interact ‘face to face’ with the numerous exhibitors.
Plant tour
This year we have an exciting announcement regarding the plant tour. For the fi rst time in conference history, we will have multiple plant tours including an international plant tour! Because the conference will be virtual, what better way to see plants locally and abroad? We are so excited for this addition to the conference and for the plant tours to close out each day of the General Session at the 63rd Annual IEEE-IAS/PCA Cement Industry Technical Conference.
Menzel has been building motors for the cement industry since 1927
Our vast experience and comprehensive expertise allow us to build you the machine you need - when you need it.
We specialize in the manufacture of customizable AC and DC electric motors. Our designs are built to meet your exacting installation and performance requirements - no matter how demanding the conditions. At MENZEL we know that time is money. Our team is able to provide you with the motor you need within weeks and in some cases days!
Electric motors up to 13.800 V. For mills, crushers, processing equipment, fans etc.
Engineered enclosures from ODP to TWAC – to meet your environment • Squirrel cage motors up to 30,000 HP • Slip ring motors up to 20,000 HP • DC motors up to 3,000 HP
Fast delivery and response times.
24/7 emergency service with motors to 10,000 HP available from stock. Cement plant references available upon request. We want you to feel secure in your decision to use MENZEL. It is our goal to create clients for life!
Contact us today for your motor needs!
MENZEL Elektromotoren GmbH | Neues Ufer 19-25 10553 Berlin-Germany | Tel. +49-30-349922-0 | Fax: -999
www.menzel-motors.com
AD INDEX AD INDEX
4B Components Ltd www.go4b.com/usa ABC www.abc.org.uk Alimak www.alimak.com
ATD Abbausysteme GmbH www.atd-cardox.de / www.atd-pgs.com AUGWIND www.aug-wind.com BEUMER Group www.beumergroup.com B.S.P. Engineering www.bspengineering.it CalPortland www.calportland.com CemCat www.cemcat.com
Cement Performance International www.cementperformance.com Christian Pfeiffer www.christianpfeiffer.com Cintasa www.cintasa.com
DCL www.dclinc.com
EnergyGlobal www.energyglobal.com ES Processing www.es-processing.com Euromecc www.euromecc.com
FLSmidth www.fl smidth.com
HEKO www.heko.com
IAC www.iac-intl.com
IEEE Cement Conference www.cementconference.org KHD Humboldt Wedag www.khd.com
OBC
54
101
93
63
49
81
13
IBC
21
43
83
87
89
87
37
OFC, 29
02
09
58 – 59
27
Köppern www.koeppern.de Lindner www.lindner.com
Magotteaux www.magotteaux.com MDG Handling Solutions www.mdghandlings.com Menzel Elektromotoren GmbH www.menzel-motors.com
Mole•Master www.molemaster.com
NAK Kiln Services www.nak-kiln.com
National Filter Media www.nfm-fi lter.com
ProcessBarron www.processbarron.com RD42 Engineering www.rd42.com
SILICON www.silicon.nu
Silobau Thorwesten GmbH www.thorwesten.com
Stela Laxhuber GmbH www.stela.de
Taiheiyo Engineering www.taiheiyo-eng.co.jp/en/ Unitherm Cemcon www.unitherm.at
UNTHA Shredding Technology www.untha.com
Vezér Industrial Professionals www.vezervip.com Waste Knot Energy www.wasteknotenergy.com WestRock www.westrock.com
World Cement www.worldcement.com
