Automated Process Control System (APCS) for cement production and packaging, automation of grinding units

APCS for an innovative cement production plant with two parallel production lines (25 tons per hour each), with storage and packing departments. ASA provided a turnkey solution for the customer: design, engineering, supply and manufacturing, PLC, HMI, SCADA software development, assembling, and commissioning.

A feature of the technology was the use of an energy-efficient drum-roll mill instead of a ball mill.

Key functions of APCS:

• Manual and automatic control of all operations in a technological cycle at the raw materials department, calcinating shop, storage of raw materials, cement grinding shop, ready-made product warehouse, and packaging department.
• Execution phases of a mission profile of starting and stopping processes.
• Adherence to predetermined standards of high-quality output performance.
• Quality control of incoming raw materials and finished products, workability of processing conditions, preparing better for emergency situations by failure prediction.
• End-to-end accounting of raw materials and finished products at all stages of the manufacturing process.

Cement manufacturing processes are controlled using highly reliable operator panels with graphic displays showing the status of currently running processes.