Siemens provides various products for cement manufacturing processes including [1] busbar trunking systems, contactors, and circuit breakers for power distribution; [2] gear units, gear motors, and couplings for mechanical drives; [3] AC motors and drives to power fans, pumps, mills, and other machines; [4] PLCs and sensors for automation and process control throughout cement production.

2. SIEMENS
Energy Industry Healthcare
IS IA / DT
LP GP IS
CE & BTLV
MD LDI
AS SC

4. SIVACON 8PS Bus Bar Trunking System
 LR System(630A to 6300A)
 LX System (800A to 6300A)
 LD System (1100A TO 5000A)
 BD2 System (160A to 1250A)
 BD01 System (40A to 160A)
 CD-K System (25 to 40A)

5. Contactors
 A contactor is an electrically controlled
switch used for switching a power
circuit, similar to relay except with higher
current ratings.
 To control electric motors,
lighting, heating, capacitor
banks, and other electrical
loads.

6. Circuit Breakers
 A circuit breaker is an automatically operated
electrical switch designed to protect an
electrical circuit from damage used by
overload or short circuit.
 Types of Circuit Breakers:
ACB
MCCB
MCB

8. Gearbox
 A gearbox provides speed and torque
conversions from a rotating power source to
another device using gear ratios.
 Types of Gearbox:
Bevel
Helical
Planetary
Worm
Spur

9. Gear Motor
 A gear motor is a type of electrical motor. It
uses the magnetism induced by an electrical
current to rotate a rotor that is connected to a
shaft. The energy transferred from the rotor
to the shaft is then used to power a
connected device.

10. Coupling
 A coupling is a device used to connect two
shafts together at their ends for the purpose of
transmitting power. The primary purpose of
couplings is to join two pieces of rotating
equipment while permitting some degree of
misalignment or end movement or both.

12. AC Drives:
 AC drives or VFDs or AFDs or Inverters are used
to control the speed of an AC motor. In other
words we can say that AC drives are used to
eliminate torque so that the motor can work
more efficiently, without losing energy.

13. Types of AC Drives (w.r.t inverter):
 VVI
 CSI
 PWM

15. PLC:
 A programmable logic controller (PLC)
or programmable controller is a digital
computer, automation of electromechanical
processes, such as control of machinery on
factory assembly lines, amusement rides, or
lighting fixtures.

16. SIMATIC Controllers:
 LOGO!
 S7 200
 S7 300
 S7 400
 S7 1200

17. Assignment….

18. Cement Manufacturing Flow sheet

19. Cement Manufacturing Process
1. The cement manufacturing process begins
when limestone, the basic raw material used to
make cement, is is either quarried from an
open pit quarry or mined from an underground
mine.

20. Cement Manufacturing Process
2. Limestone should be crushed and grinded
before further usage. Crusher reduces the size
of the limestone from 1m to 15 mm size.

21. Cement Manufacturing Process
3. The limestone is combined with clay, ground in a
crusher and fed into the additive silos.
Sand, iron and bottom ash are then combined
with the limestone and clay in a carefully
controlled mixture which is ground into a fine
powder in a 2000 hp roller mill.

22. Cement Manufacturing Process
4. Next, the fine powder is heated as it passes through the
Pre-Heater Tower into a large kiln, which is over half the
length of a football field and 4.2 meters in diameter. In
the kiln, the powder is heated from 1350 to 1450
degrees Celsius. This creates a new product, called
clinker, which resembles pellets about the size of
marbles.

23. Cement Manufacturing Process
5. The clinker is combined with small amounts of
gypsum and limestone and finely ground in a
finishing/grinding/ball mill. The mill is a large
revolving cylinder containing 250 tons of steel
balls that is driven by a 4000 hp motor.

24. Cement Manufacturing Process
6. Now, the cement is ready for storage into the
cement silos. From silos the cement is moved to
packing plant for packing, distribution and
shipping.

25. Cement Process Analysis
 CE & BTLV Products:
1. Air circuit breakers (ACBs) in the low-voltage main
switchboard ensure the power distribution in a cement plant.
2. Using SIVACON 8PS bus bar trunking system, space saving
power distribution for production halls/storage halls is
possible. BD02 can be used as power backbone (main
distribution), BD01 for lighting, LD system can also be applied
power distribution, LR system for rough ambient conditions.
3. Contractors, overload relays & soft starters can be used for
motors protection.
4. Push button units, indicators & signaling columns can be used
for EMERGENCY-STOP and in the control room for monitoring
complex procedures.

26. Cement Process Analysis
 MD Products:
1. BEVEL-HELICAL GEAR UNITS or HELICAL GEAR
UNITS can be applied at Conveyor drives & Bucket
elevator drives.
2. PLANETARY GEAR UNITS can be applied at Rotary
kiln drive, Bucket wheel drives, Apron conveyor
drives.
3. COUPLINGS can be applied for transmission
between drives at Conveying
systems, Mixers, Crushers, Bucket wheel
excavators.
4. GEAR MOTORS can also be applied to Conveyor
drives, Bucket elevator drives.

27. Cement Process Analysis
 LDI Products:
1. AC MOTORS can be applicable with the gear units.
2. AC DRIVES can be applied to
• Fans
• Pumps
• Grinding mills
• Kilns
• Crushers
• Conveyors
• Mine hoists

28. Cement Process Analysis
 AS Products:
1. SIMATIC controllers / PLCs can be used for
controlling machines, exhaust and filtering
systems, conveyor systems, elevators, Silo
facilities, vehicle control monitoring, alarm
systems, level limiting monitoring, baggage
handling, interior/exterior lighting
control, door gate control etc.
2. SIPLUS versions for harsh environment.

29. Cement Process Analysis
 SC Products:
1. SITRANS family can be applied at various
processes throughout the cement industry.
For instance:
2. For flow measurement at silos, grinding
mills, kiln, clinker cooler etc.
3. For temperature
limiting, monitoring, measuring preheating
tower, kiln & clinker cooler.
4. Also for process controlling, level
monitoring, pressure controlling etc.

30. Presented by….