International Journal on Emerging Technologies (Special Issue on NCRIET-2015) 6(2): 42-47(2015) ISSN No. (Print) : 0975-8364 ISSN No. (Online) : 2249-3255 PLC Based Automated Clinker Cooling System for Cement Manufacturing Industry B. Ravikant, S. H. Mangala**and A V. Sutagundar* *Department of E & CE, BEC, Bagalkot INDIA **Department of E & CE, PESITM, Shivamogga, INDIA (Corresponding author: B. Ravikant) (Published by Research Trend, Website: www.researchtrend.net) ABSTRACT: Cement Industry is a very big Industry. It has many sub-units, in which some are fully automated and some are semi-automated. These fully automated sub-units are controlled by Programmable Logic Controller (PLC). The aim of this paper is to convert the semi- automated clicker cooling systems into clicker cooling fully. Pre-Heater is a process in which materials are subjected to high temperatures at 1400 to 1500oC to bring a chemical change. This is fed into the Kiln. Kiln is a hollow cylinder with refractory lining rotating at variable speed. The temperature inside the kiln is 1300 to 1400 oC and the material undergoes various reactions. The product obtained from the Kiln is called Clinker. Coolers are used to cool the clinkers to a temperature of about 300oC. This automated system is automated using PLC. The proposed system is simulated using INDRA WORKS Engineering, which is firmware of BOSCH REXROTH PLC’s. I. INTRODUCTION Cements Industry was a very big fully automated industry and it is controlling by PLC. The raw materials of cement are calcium carbonate, Silica, alumina and iron which are generally extracted from Limestone rock [1], chalk, and clay. These raw materials are extracted from the quarry by blasting. Some of the processes of cement industry are as follows: A. Raw material (Limestone) Crush Capacity: 950 tons per hour. To crush the raw materials Hydraulics of 150 bar pressure is used the crushed lime stone of size less than 10mm is transported through conveyor to the limestone stock pile to stack under covered shed through tipper conveyor. From the limestone stock pile material with uniform quality will be transported to hopper through belt conveyor. B. Hoppers There are three Hoppers in which two bigger hoppers are limestone hoppers and comparatively small hopper is iron hopper [2]. If the iron content is less in the mixture, then it automatically adds iron in the required quantity. C. Raw mill and Ball meal preparation Raw mill is a ball mill meant for grinding limestone, latertite and iron ore of size below 10mm to less than 212 micron size this powdered material is called “raw meal” and is transported to storage silo. D. Blending Silo and Kiln feed extraction system Silo is meant for the storage of raw meal powder produced by raw mill and also facilitates blending through aeration system to homogenize and maintain consistent quality of raw meal. Homogenized raw mill from the silo transported to kiln feed bin. From kiln feed bin the raw ...

1. International Journal on Emerging Technologies (Special Issue
on NCRIET-2015) 6(2): 42-47(2015)
ISSN No. (Print) : 0975-8364
ISSN No. (Online) : 2249-3255
PLC Based Automated Clinker Cooling System for Cement
Manufacturing Industry
B. Ravikant, S. H. Mangala**and A V. Sutagundar*
*Department of E & CE, BEC, Bagalkot INDIA
**Department of E & CE, PESITM, Shivamogga, INDIA
(Corresponding author: B. Ravikant)
(Published by Research Trend, Website: www.researchtrend.net)
ABSTRACT: Cement Industry is a very big Industry. It has
many sub-units, in which some are fully
automated and some are semi-automated. These fully automated
sub-units are controlled by
Programmable Logic Controller (PLC). The aim of this paper is
to convert the semi- automated clicker
cooling systems into clicker cooling fully. Pre-Heater is a
process in which materials are subjected to high
temperatures at 1400 to 1500oC to bring a chemical change.
This is fed into the Kiln. Kiln is a hollow
cylinder with refractory lining rotating at variable speed. The
temperature inside the kiln is 1300 to 1400
oC and the material undergoes various reactions. The product
obtained from the Kiln is called Clinker.

2. Coolers are used to cool the clinkers to a temperature of about
300oC. This automated system is
automated using PLC. The proposed system is simulated using
INDRA WORKS Engineering, which is
firmware of BOSCH REXROTH PLC’s.
I. INTRODUCTION
Cements Industry was a very big fully automated
industry and it is controlling by PLC. The raw
materials of cement are calcium carbonate, Silica,
alumina and iron which are generally extracted from
Limestone rock [1], chalk, and clay. These raw
materials are extracted from the quarry by blasting.
Some of the processes of cement industry are as
follows:
A. Raw material (Limestone) Crush
Capacity: 950 tons per hour. To crush the raw
materials Hydraulics of 150 bar pressure is used the
crushed lime stone of size less than 10mm is
transported through conveyor to the limestone stock
pile to stack under covered shed through tipper
conveyor. From the limestone stock pile material with
uniform quality will be transported to hopper through
belt conveyor.
B. Hoppers
There are three Hoppers in which two bigger hoppers
are limestone hoppers and comparatively small
hopper is iron hopper [2]. If the iron content is less in
the mixture, then it automatically adds iron in the
required quantity.
C. Raw mill and Ball meal preparation
Raw mill is a ball mill meant for grinding limestone,

3. latertite and iron ore of size below 10mm to less than
212 micron size this powdered material is called “raw
meal” and is transported to storage silo.
D. Blending Silo and Kiln feed extraction system
Silo is meant for the storage of raw meal powder
produced by raw mill and also facilitates blending
through aeration system to homogenize and maintain
consistent quality of raw meal. Homogenized raw mill
from the silo transported to kiln feed bin. From kiln
feed bin the raw mill conveyed to the top of the pre
heater through belt conveyor.
E. Pre-Heater and Cooler
Pre-Heater is a 7 storey building with Pre-calciner,
cyclones, mixing chamber, feed pipes and ducts. This
is heated from 70 degrees to 1000 degrees.
Calcinations are the dissociation of limestone into
lime and carbon dioxide.
This entered hot material in converted at 1350- 1400
degrees to clinker after passing through various
phases.
The cooler is meant for cooling hot clinker which is
discharged from with 1100 to 150 degree centigrade
by centrifugal fans. Ambient air is pumped into cooler
through fans at bottom side of grate pass through hot
clinker bed.
Fly ash is added to clinker as per required percentage
in the process of cement grinding. Cement mill is
meant for grinding the clinker, fly ash and gypsum to
a powder from around 320 sq.mt/kg. The fine powder
is called cement. All over, this Industry is controlled
by PLC which can be seen in lab.
In this paper we are controlling automated clinker
cooling system using PLC.

4. et
www.researchtrend.net
Ravikant, Mangala and Sutagundar 43
Section 2 presents the proposed work, section 3 gives
the various sensors used in the proposed system,
section 4 describes the block diagram for clinker
cooling system using PLC. In section 5 PLC based
ladder diagram for the automation of clinker cooling
system is presented. Section 6 concludes the work.
II. PROPOSED WORK
This section presents the three sub parts of proposed
system, section 2.1 describes the Clinkerisation, 2.2
presents Clinker Coolers, and 2.3 presents Flow
Chart.
A. Clinkerisation
Materials fed to the pre-heater tower are allowed to
pass through a four stage suspension pre-heater which
consists of several cyclones. The cyclonic action is
generated with the help of suction of pre-heater fan.
The hot gases from the kiln are sucked and passed
such that the materials are heated to a temperature of
about 300 to 4000C at the top and 900 to 10000C at
the bottom.
Due to gravitational effect in the material discharged
downwards are fed to the kiln. Kiln is a hollow
cylinder with refractory lining rotating at variable
speed [2]. Inside the kiln the materials undergo
various reactions. The process taking place inside the
kiln is called calcinations. Inside the kiln the

5. temperature is about 1300 to 1400 oC. The product
obtained from the kiln is called clinker. Grate cooler
cools the clinker to a temperature of about 100 to 150
oC. The clinker is transported to the stockpile through
bucket conveyor and stored there.
B. Clinker Coolers
Clinker coolers are classified into different types
based on their design and operation. The classification
of clinker cooling mechanisms is as given in figure 1.
Fig. 1. Classification of Clinker coolers.
Grate Cooler. Grate coolers are extensively used in
cement industry to recover heat from hot clinkers
coming out of rotary kilns. Heat transfer in coolers
indirectly controls the performance of the rotary kiln
and is therefore crucial in a cement industry. The
outlet temperature of hot clinkers and a part of melt
coming out from the rotary kiln is approximately 1673
K. These hot clinkers should be cooled to a
temperature around 400 K, by recovering heat from
them, which can be used for any other process [3][4].
In the same time the combustion air required for the
burning process should be preheated to a temperature
level such that the fuel consumption for clinker
formation in the rotary kiln is minimum. So to fulfil
both the purposes grate coolers are used in cement
industries.
Working
Fig. 2. Schematic diagram of grate cooler.
Figure 2 shows the schematic diagram of grate cooler.

6. Reciprocating grate cooler is one of main equipments
for cement production burning system; its function is
cooling hot clinker, reclaiming clinker sensible heat
and conveying clinker. It works in a condition of high
temperature and variability.
The cooler grate is composed of overlapping rows of
perforated grate plates. Half of the rows are static,
fixed to the casing of the cooler [4]. The alternate
rows are carried on a movable frame to which a
reciprocating movement is imparted by an eccentric
drive or hydraulic rams. The overlying bed of clinker
is pushed forward on the forward stroke, and the
plates slide beneath the bed on the return stroke. Fine
clinker can fall though the grate holes, and so the
under-grate chamber contains drag-chain conveyor(s)
to move the spillage to the outlet end of the cooler.
For most of its history, a crusher, usually in the form
of a hammer mill, has been placed at the end of the
cooler.
Ravikant, Mangala and Sutagundar 44
Larger clinker lumps, with a low surface area, are less
effectively cooled, and having been crushed, the
rotary action of the hammer mill hurls the fragments
back up the cooler for further cooling.
The under-grate chamber is generally divided into a
number of compartments, each with its own fan,
which can be separately pressurised. The chamber
above the grate is refractory lined. Areas of cold,
"dead" clinker are provided at the sides of the grate to
protect those areas from over-heating. The hot air
emerging from the bed passes out to the kiln, and the
hot-end grate pressure is controlled to provide a small

7. negative pressure in the kiln hood. Because, in
general, more air passes through the grate than can be
used by the kiln, outlet ducts are provided on the side
of the cooler parts of the over-grate chamber[5]. The
hot air passing out through these may be used
productively for process operations - e.g. for fuel or
raw material drying - or may simply be run to waste
through an exhaust stack. The hot air is inevitably
heavily loaded with fine clinker grit, and so some sort
of gas cleaning is provided prior to the stack. Both
sloping and horizontal grates may be used. The
original design had a 12° slope. Since all kilns,
irrespective of process, deliver clinker at around
1300°, the size of cooler required is solely related to
the expected kiln output, and grates are typically
designed for a loading of 30 t/d per m2 - i.e. a kiln
making 1800 t/d would require a grate area of 60 m2.
Spray Cooler. Figure 3 shows the schematic diagram
of spray cooler. The spray cooler is the emergency
cooling system used when the temperature of the
clinker exiting the grate cooler is still greater than
6000 C. The temperature at the exit is sensed by a_J
type THERMOCOUPLE. The system is equipped
with a water tank, spray pump, a level switch to detect
when water level in the tank is low, flow switch to
check flow of water through the pump,3 temperature
control valves which are opened when clinker
temperature exceeds the limit and a flow nozzle to
spray water. The flow switch is activated when there
is no flow through the pump and generates alarm [5].
Level switch is activated when the water level in the
tank is low and generates the corresponding alarm
.There is a 3 way valve to provide bypass to the tank
which is pneumatically actuated. The other 2 valves
are 2 way valves out of which one is pneumatically
actuated and the other is electrically actuated .There is

8. a pressure switch used to generate the alarm when the
pressure in the compressor is low.
Fig. 3. Spray Cooler.
C. Flow Chart
Ravikant, Mangala and Sutagundar 44
Larger clinker lumps, with a low surface area, are less
effectively cooled, and having been crushed, the
rotary action of the hammer mill hurls the fragments
back up the cooler for further cooling.
The under-grate chamber is generally divided into a
number of compartments, each with its own fan,
which can be separately pressurised. The chamber
above the grate is refractory lined. Areas of cold,
"dead" clinker are provided at the sides of the grate to
protect those areas from over-heating. The hot air
emerging from the bed passes out to the kiln, and the
hot-end grate pressure is controlled to provide a small
negative pressure in the kiln hood. Because, in
general, more air passes through the grate than can be
used by the kiln, outlet ducts are provided on the side
of the cooler parts of the over-grate chamber[5]. The
hot air passing out through these may be used
productively for process operations - e.g. for fuel or
raw material drying - or may simply be run to waste
through an exhaust stack. The hot air is inevitably
heavily loaded with fine clinker grit, and so some sort
of gas cleaning is provided prior to the stack. Both
sloping and horizontal grates may be used. The
original design had a 12° slope. Since all kilns,
irrespective of process, deliver clinker at around
1300°, the size of cooler required is solely related to
the expected kiln output, and grates are typically

9. designed for a loading of 30 t/d per m2 - i.e. a kiln
making 1800 t/d would require a grate area of 60 m2.
Spray Cooler. Figure 3 shows the schematic diagram
of spray cooler. The spray cooler is the emergency
cooling system used when the temperature of the
clinker exiting the grate cooler is still greater than
6000 C. The temperature at the exit is sensed by a_J
type THERMOCOUPLE. The system is equipped
with a water tank, spray pump, a level switch to detect
when water level in the tank is low, flow switch to
check flow of water through the pump,3 temperature
control valves which are opened when clinker
temperature exceeds the limit and a flow nozzle to
spray water. The flow switch is activated when there
is no flow through the pump and generates alarm [5].
Level switch is activated when the water level in the
tank is low and generates the corresponding alarm
.There is a 3 way valve to provide bypass to the tank
which is pneumatically actuated. The other 2 valves
are 2 way valves out of which one is pneumatically
actuated and the other is electrically actuated .There is
a pressure switch used to generate the alarm when the
pressure in the compressor is low.
Fig. 3. Spray Cooler.
C. Flow Chart
Ravikant, Mangala and Sutagundar 44
Larger clinker lumps, with a low surface area, are less
effectively cooled, and having been crushed, the
rotary action of the hammer mill hurls the fragments
back up the cooler for further cooling.
The under-grate chamber is generally divided into a
number of compartments, each with its own fan,

10. which can be separately pressurised. The chamber
above the grate is refractory lined. Areas of cold,
"dead" clinker are provided at the sides of the grate to
protect those areas from over-heating. The hot air
emerging from the bed passes out to the kiln, and the
hot-end grate pressure is controlled to provide a small
negative pressure in the kiln hood. Because, in
general, more air passes through the grate than can be
used by the kiln, outlet ducts are provided on the side
of the cooler parts of the over-grate chamber[5]. The
hot air passing out through these may be used
productively for process operations - e.g. for fuel or
raw material drying - or may simply be run to waste
through an exhaust stack. The hot air is inevitably
heavily loaded with fine clinker grit, and so some sort
of gas cleaning is provided prior to the stack. Both
sloping and horizontal grates may be used. The
original design had a 12° slope. Since all kilns,
irrespective of process, deliver clinker at around
1300°, the size of cooler required is solely related to
the expected kiln output, and grates are typically
designed for a loading of 30 t/d per m2 - i.e. a kiln
making 1800 t/d would require a grate area of 60 m2.
Spray Cooler. Figure 3 shows the schematic diagram
of spray cooler. The spray cooler is the emergency
cooling system used when the temperature of the
clinker exiting the grate cooler is still greater than
6000 C. The temperature at the exit is sensed by a_J
type THERMOCOUPLE. The system is equipped
with a water tank, spray pump, a level switch to detect
when water level in the tank is low, flow switch to
check flow of water through the pump,3 temperature
control valves which are opened when clinker
temperature exceeds the limit and a flow nozzle to
spray water. The flow switch is activated when there
is no flow through the pump and generates alarm [5].

11. Level switch is activated when the water level in the
tank is low and generates the corresponding alarm
.There is a 3 way valve to provide bypass to the tank
which is pneumatically actuated. The other 2 valves
are 2 way valves out of which one is pneumatically
actuated and the other is electrically actuated .There is
a pressure switch used to generate the alarm when the
pressure in the compressor is low.
Fig. 3. Spray Cooler.
C. Flow Chart
Ravikant, Mangala and Sutagundar 45
Explanation of Flowchart
Figure 4 shows the flow chart of proposed work. The
first step is to the level is. If it is low, the alarm turns
on. Then next the pressure is checked. If it is low, the
alarm turns on, and spray pump is also turns on. The
flow is checked. If the flow is low, the alarm turns on.
The running sequences of cooler parts are fixed as
cooling fan1, 2, 3&4. Drag chain, clinker crusher,
cooler1 &cooler2.The stopping sequence are in the
reverse order. This is so that the motion of the parts is
not obstructed by the clinker remains if any.
The overload and stop criteria of the quenching fan
and two cooling fans are checked. If both are on the
quenching fan and the two cooling fans are turned off.
Otherwise it is turned on. The overload and stop
criteria of the drag chain, crusher, cooler1, cooler2,
and the third cooling fan are checked. If both are on
the drag chain, crusher, cooler1, cooler2, and the third
cooling fan are turned off. Otherwise it is turned on.

12. Drag chain is turned on. Zero speed is checked. If it is
on, the drag chain is turned off. If zero speed is off, a
feedback is given and then delay is given. Clinker
crusher is turned on. Zero speed is checked. If it is on,
the drag chain is turned off.
If zero speed is off, a feedback is given and then delay
is given. Cooler 2 is turned on. Zero speed is checked.
If it is on, the drag chain is turned off.
Fig. 4. Flow chat.
If zero speed is off, a feedback is given and then delay
is given. Similarly cooler 1 is turned on. Run the third
cooling fan at 40% speed. Then a feedback is given
and then the cooling fan is turned off. The cooling fan
is given the set point speed. If the speed is greater
than the set point speed then a decreasing speed is
given otherwise an increasing speed is given. Cooler 2
is given the set point speed. If the speed is greater
than the set point speed then a decreasing speed is
given otherwise an increasing speed is given. The
same check is done for cooler 1 also. If the cooler
temperature is greater than the set point, temperature
control valves are open otherwise it is closed.
III. SENSORS USED
This section explains the four types of sensors used in
the cooler system. Section explains the thermocouple
sensor, describe the RF level detector sensor, presents
bellow type pressure sensor, and paddel type flow
switch.
A. Thermocouple
J type thermocouple is used near to the exit portion of

13. grate cooler system to measure the temperature. The
output of thermocouple is used to actuate the spray
cooler system under emergency conditions.
Ravikant, Mangala and Sutagundar 45
Explanation of Flowchart
Figure 4 shows the flow chart of proposed work. The
first step is to the level is. If it is low, the alarm turns
on. Then next the pressure is checked. If it is low, the
alarm turns on, and spray pump is also turns on. The
flow is checked. If the flow is low, the alarm turns on.
The running sequences of cooler parts are fixed as
cooling fan1, 2, 3&4. Drag chain, clinker crusher,
cooler1 &cooler2.The stopping sequence are in the
reverse order. This is so that the motion of the parts is
not obstructed by the clinker remains if any.
The overload and stop criteria of the quenching fan
and two cooling fans are checked. If both are on the
quenching fan and the two cooling fans are turned off.
Otherwise it is turned on. The overload and stop
criteria of the drag chain, crusher, cooler1, cooler2,
and the third cooling fan are checked. If both are on
the drag chain, crusher, cooler1, cooler2, and the third
cooling fan are turned off. Otherwise it is turned on.
Drag chain is turned on. Zero speed is checked. If it is
on, the drag chain is turned off. If zero speed is off, a
feedback is given and then delay is given. Clinker
crusher is turned on. Zero speed is checked. If it is on,
the drag chain is turned off.
If zero speed is off, a feedback is given and then delay
is given. Cooler 2 is turned on. Zero speed is checked.
If it is on, the drag chain is turned off.
Fig. 4. Flow chat.

14. If zero speed is off, a feedback is given and then delay
is given. Similarly cooler 1 is turned on. Run the third
cooling fan at 40% speed. Then a feedback is given
and then the cooling fan is turned off. The cooling fan
is given the set point speed. If the speed is greater
than the set point speed then a decreasing speed is
given otherwise an increasing speed is given. Cooler 2
is given the set point speed. If the speed is greater
than the set point speed then a decreasing speed is
given otherwise an increasing speed is given. The
same check is done for cooler 1 also. If the cooler
temperature is greater than the set point, temperature
control valves are open otherwise it is closed.
III. SENSORS USED
This section explains the four types of sensors used in
the cooler system. Section explains the thermocouple
sensor, describe the RF level detector sensor, presents
bellow type pressure sensor, and paddel type flow
switch.
A. Thermocouple
J type thermocouple is used near to the exit portion of
grate cooler system to measure the temperature. The
output of thermocouple is used to actuate the spray
cooler system under emergency conditions.
Ravikant, Mangala and Sutagundar 45
Explanation of Flowchart
Figure 4 shows the flow chart of proposed work. The
first step is to the level is. If it is low, the alarm turns
on. Then next the pressure is checked. If it is low, the
alarm turns on, and spray pump is also turns on. The

15. flow is checked. If the flow is low, the alarm turns on.
The running sequences of cooler parts are fixed as
cooling fan1, 2, 3&4. Drag chain, clinker crusher,
cooler1 &cooler2.The stopping sequence are in the
reverse order. This is so that the motion of the parts is
not obstructed by the clinker remains if any.
The overload and stop criteria of the quenching fan
and two cooling fans are checked. If both are on the
quenching fan and the two cooling fans are turned off.
Otherwise it is turned on. The overload and stop
criteria of the drag chain, crusher, cooler1, cooler2,
and the third cooling fan are checked. If both are on
the drag chain, crusher, cooler1, cooler2, and the third
cooling fan are turned off. Otherwise it is turned on.
Drag chain is turned on. Zero speed is checked. If it is
on, the drag chain is turned off. If zero speed is off, a
feedback is given and then delay is given. Clinker
crusher is turned on. Zero speed is checked. If it is on,
the drag chain is turned off.
If zero speed is off, a feedback is given and then delay
is given. Cooler 2 is turned on. Zero speed is checked.
If it is on, the drag chain is turned off.
Fig. 4. Flow chat.
If zero speed is off, a feedback is given and then delay
is given. Similarly cooler 1 is turned on. Run the third
cooling fan at 40% speed. Then a feedback is given
and then the cooling fan is turned off. The cooling fan
is given the set point speed. If the speed is greater
than the set point speed then a decreasing speed is
given otherwise an increasing speed is given. Cooler 2
is given the set point speed. If the speed is greater
than the set point speed then a decreasing speed is
given otherwise an increasing speed is given. The
same check is done for cooler 1 also. If the cooler

16. temperature is greater than the set point, temperature
control valves are open otherwise it is closed.
III. SENSORS USED
This section explains the four types of sensors used in
the cooler system. Section explains the thermocouple
sensor, describe the RF level detector sensor, presents
bellow type pressure sensor, and paddel type flow
switch.
A. Thermocouple
J type thermocouple is used near to the exit portion of
grate cooler system to measure the temperature. The
output of thermocouple is used to actuate the spray
cooler system under emergency conditions.
Ravikant, Mangala and Sutagundar 46
Type J (iron–constantan) has a more restricted range
than type K (−40 to +750 °C), but higher sensitivity of
about 55 μV/°C. The Curie point of the iron (770°C)
causes an abrupt change in the characteristic, which
determines the upper temperature limit.
B. RF Level Detector
Capacitance level detectors are also referred to as
radio frequency (RF) or admittance level sensors [5].
They operate in the low MHz radio frequency range,
measuring admittance of an alternating current (ac)
circuit that varies with level.
C. Bellow type Pressure Sensor

17. A pressure switch is used to detect the presence of
fluid pressure. Most pressure switches use a
diaphragm or bellow as the sensing element. The
movement of this sensing element is used to actuate
one or more switch contacts to indicate an alarm or
initiate a control action.
D. Paddle type Flow Switch
Gas or Liquid flow is sensed by the freely suspended
disc via bellow-sealed designs which create the
movement of Disc against the force. A precision
spring guarantees repeatability and high effectiveness
of operation. To ensure positive isolation between
switch assembly and process fluid, bellow is sealed
[4]. Flow Paddle Switches are repeatedly tested for
maximum pressure of 10 Bar and are highly suitable
for temp. Up to 200°C. The process connection for
Paddle type is 1" BSP (M) standard and for on-line
type is %" BSP (F) std.
IV. AUTOMATED CLINKER COOLING
SYSTEM BLOCK DIAGRAM
Fig. 5. Automated clinker cooling system using PLC.
V. LADDER DIAGRAM
Fig. 6. Ladder diagram of clinker cooling system.
Table 1: Inputs and outputs of proposed work.
VI. CONCLUSION
PLC based automated Clinker cooling system used in

18. cement manufacturing Industry is the application of
PLC. PLC and its related circuits provides an options
and logical diagnostic so as to provide a reliable,
versatile and safety to control various operations of
Clinker cooling system.
Ravikant, Mangala and Sutagundar 47
REFERENCES
[1]. Anil Kumar Udugu, Dr. Anand Khare “Automation of
Cement Industries” in proceedings of IJREAT International
Journal of Research in Engineering & Advanced
Technology, Volume1, Issue 6, Dec-Jan, 2014.
[2]. B.T.D. Praveen Varma, K.P. Sirisha “Study of
Processing and Machinery in Cement Industry” in
proccedings of International Journal of Engineering and
Innovative Technology (IJEIT) Volume 3, Issue 5,
November 2013.
[3]. Ruchi Harchandani, Bindu R “Automation of Kiln Mill
Drive in Cement Industry using PLC and SCADA” in
proceedings of International Journal of Engineering
Research & Technology (IJERT) Vol. 3 Issue 1, January –
2014.
[4]. C.D. Johnson, ―Process Control instrumentation
Technology‖, seventh edition, prentice-hall of India pvt.ltd.
[5]. B G LIPTAK, ―Instrument Engineer’s Hand Book‖,
third edition, Chilton book company Pennsylvania.
Control Systems Case Study Report and Information

19. Semester 1, 2020 1 Copyright © Edith Cowan University
CASE STUDY REPORT
CONTROL SYSTEMS
Ref: Kirkup (1994). Experimental Methods: An Introduction to
the Analysis and
Presentation of Data. Brisbane: John Wiley & Sons.
A case study report is required to be submitted by each student
as one of the
assessment items for this unit. The report will be assessed and
marked out of 10%.
The format of the report is that of an engineering/scientific
report. All aspects of your
report must be your own original work. You must acknowledge
any assistance that
you received, and must provide appropriate referencing for any
copyright information
that you include in your report.
One of the primary goals of the project is to get you to perform
“inquiry or problem-
based learning” through this project. You investigate the
problem, and when you reach
the limit of your knowledge, you will need to backtrack and re-
examine the problem.
You should determine explicitly what you need to know at each
stage, and then search
for information from the sources at your disposal – the lecture
notes, textbook, other
references, the library, the internet, etc. We understand that you
may not know
everything you need to know at this stage, but your learning

20. should accelerate as you
progress through the project.
What Your Report Should Contain
You are required to include the following information, and
structure your report as
described:
Assignment Cover Sheet – download from the Unit page on
Blackboard.
Case Study Report Template – download from the Unit page on
Blackboard then:
• Edit the Word file and adjust it to your project realisation.
• Keep the number of words within the limits indicated next to
each paragraph title.
• Follow the guidelines below and keep the report as
professional as possible.
Introduction
• Short summary of the purpose or function of your proposed
system – what goals
are you trying to achieve.
• Include background information on previous work, including
references.
Case Description
• Description of the procedures and apparatus to be used.
Include a diagram of your
proposed case study.

21. • Based on the case study goals, define what you intend to
control. Include a
description of the operating range (and any other properties) of
your defined control
processes.
• If you use software, describe the software and what you need
to include in the
software to achieve your stated goals. You should map out a
plan of the functions
you want the software to perform. This can be a flow diagram.
Control Systems Case Study Report and Informa tion
Semester 1, 2020 2 Copyright © Edith Cowan University
References
Reference all material that you use from other sources. Use the
correct referencing
method defined by the University (or Kirkup)*.
Appendix
• Include any information that you feel is important for
interpreting the report that does
not actually belong in the body of the report; i.e. important
datasheets and other
equipment information.
Overall Organization and Presentation
• Use a word processor – this makes editing and rewriting easy
and efficient – it
also allows you to submit the report electronically. This also

22. allows you to pass
copies of the report between group members so that everyone
can contribute to the
editing. Your report must be submitted individually as a
Microsoft Word formatted
file or a PDF file (preferred).
• Length: The length of your report should have a maximum of
twenty A4 pages,
single spaced, including figures (diagrams and graphs). Do not
make it too long –
use appendices if needed.
• Page Size and Margins: Page size should be A4, with margins
of 1 inch (2.5 cm) all
round.
• Font: Font size should be 12 font either Times Roman, Arial,
Courier or similar –
that is, readable.
• Page Numbers: Already at the bottom of the page of the
template file.
• Section Headings: Be consistent in the labelling of sections,
whether you use
section numbers and a heading or just a section heading.
• Where appropriate, use footnoting within the text.
• Spell correctly, and use correct grammatical structure.
• Neutral (third) or second person (“we”) – neutral is preferred.
• Do not use dot points – write proper sentences (dot points are
OK in laboratory
notebook, but not in reports).
• Paragraphs: There are two conventions for defining a
paragraph: (1) Begin

23. paragraphs on the left margin and have a blank line between
paragraphs, or (2)
indent the first line of a paragraph (0.25 to 0.5 cm) with no
blank lines between
paragraphs (or a half line between paragraphs). Be consistent in
the method you
choose.
Equations
• Create equations using an equation editor.
• Equations should be on a new line, numbered sequentially on
right, with the
line right justified. The number should be in brackets, e.g. (1).
• Identify symbols when they first appear.
• Express numbers clearly –
6*10^23.
• Use appropriate units on all numerical values.
• Express numerical values to the appropriate number of
significant figures.
• Equations form part of the text; that is, the presence of an
equation should
appear as if it is part of a sentence, even though it is on a
separate line and is
numbered. If the equation is at the end of a sentence, it should
be followed by a
full stop; if it is in the middle of a sentence, then a comma may
be required.
Control Systems Case Study Report and Information

24. Semester 1, 2020 3 Copyright © Edith Cowan University
• In the text, refer to the equation by its number. “As discussed
earlier, Equation
(1) indicates that …”
Tables
• Numbered (using roman numerals) in sequence – e.g. “Table
II”.
• Title at top of table – to right of or under table number. Again,
the title is actually
a caption that describes what the table is displaying.
• Results presented with errors (uncertainties) and units.
• Literature values (footnoted) may be included for comparison.
• Make sure that all captions stay with the appropriate table on
the same page.
• Refer to all tables appropriately with their numbers in the text;
i.e. “Table II
shows data on …” not “in the table below”.
• Tables are separate from the text.
Figures
• Create graphs with a graphing program (e.g. Excel,
MATLAB).
• Numbered (using Arabic numerals) – e.g. Fig. 1.
• Include figure caption – a description of what the figure
shows.
• Figure number and caption centred at the bottom of the figure.
• Provide a “key” or “legend” for each graph, including curve
fits (this can be
included in the figure caption).
• Axes clearly labelled, including units – use appropriate
ranges, scales and

25. number formats for axes data labels.
• The data should fill the graph.
• Data appears as symbols, trend lines appear as lines.
• You only need a legend if you plot more than one set of data.
• Refer to all figures appropriately with their numbers in the
text; i.e. “as shown in
Figure 1” not “in the diagram below”.
• Make sure that all captions stay with the appropriate figure on
the same page.
• Figures are separate from the text; embedded into the text.
*Referencing Techniques:
The University has a referencing method based on the Harvard
system. You can use
the Harvard system if you prefer. The Harvard system works
like this: (Smith, 2014).
Then in the reference section you have the list in alphabetical
order of the first author.
The advantage of this is that you don’t need to keep track of
numbers.
However, the Vancouver referencing system is the preference in
scientific and
engineering publications. A reference number is used in text
with square brackets [1].
The reference section is then a list of the references in
numerical order. You can
number them in the order they appear in your report (the
easiest) or you can have
them numbered in alphabetical order in the reference list, then
use the appropriate
number where the reference occurs in text (much more
complicated).

26. If you take a diagram or image from another copyright source,
you must include a
reference to the source of this material. Failure to do so is
plagiarism and copyright
violation.