CemWise provides operational guidance for cement plants from quarry to discharge of cement.
Our audits are road maps for sustainable improvements at different scales. They range from a quick overview of hidden potential to deep-going troubleshooting and comprehensive investigations.
No matter the scale, the commercial significance of our technical findings are always at the front of our minds.
In CemWise we prepare the grounds for implementation by carefully explaining findings and by structuring our recommendations in a practical step-by-step way. To support successful implementation, we also provide custom made packages of follow-up support for action plans and subscriptions on technical assistance.
Proposals are always tailored in close cooperation with our clients and examples of elements, that may be included, can be seen below.
For a first impression and a quick overview of where to dig deeper for hidden potential, a review of key operating parameters can be very beneficial. The assessment is made remotely based on forwarded production data with one or more teleconferences, but it may also be combined with a visit to site.
The key to a consistently high output and good quality, and to the lowest possible energy input as well, is stable operation.
Assessing the complexities of process and quality issues, we apply our state of the art process knowledge from all kinds of conditions in cement production.
We investigate and evaluate the flows of material and gases, scrutinize lab reports and quality; we make optimizations of raw mix with available raw materials and we assess capacities and compare their utilization to best practices. When relevant, we also evaluate standard operating procedures.
Maintenance is an investment into an extended lifetime of equipment and a steady output. With a high reliability, energy consumption is reduced and equipment and refractory are exposed to the least possible stress.
Investments in maintenance, however, are complex, as decisions have to be made up front, often long before the need for them becomes visible, but with good planning entailed in a high reliability, safety margins can be decreased throughout the system.
Assessing maintenance and reliability we look into inspections, measurements and analyses and their feedback loops, root cause analyses, critical spares and spare parts availability, ownership and decision making, as well as procedures for work orders and purchase.
Energy consumption typically accounts for 50 – 70% of a cement plants operating costs. An assessment of the energy efficiency will locate the operating procedures and/or equipment that may be revised or replaced to obtain a lower specific energy and heat consumption to reduce operating costs and CO2 footprint of the production.
Many times cement plants can offer a waste management solution to society, while reducing production costs by utilizing alternative raw materials and fuels. However, AFR will often have adverse effects on operation and clinker quality. Introducing AFRs should be done cautiously, and a meticulous end-to-end consideration of the consequences and possible remedies is highly recommended ahead of the introduction. In CemWise we make 360° assessments of AFR; evaluating sourcing, handling, feeding and impact on kiln system to allow for a smooth introduction and reduce negative effects on the operation.
Cement production begins in the quarry. Many challenges to operation and quality can be avoided by optimized exploitation of the quarry. Assessing quarry potential, we evaluate how to ensure the longest posible lifetime, safe and secure conditions as well as the logistics, but we may also include process considerations and possible changes to the raw mix design.
Emissions are a major concern to many cement plants. Proper conditions of the equipment are necesary to fullfil the requirements of the society for an environmentally sustainable production.
We can assist with a feasibility study of possibilities to reduce emissions, by either process optimization or renewal/addition of equipment.
In case of specific issues in the operation, CemWise will investigate and analyze these to identify solutions. All variables that may cause or contribute to the operational problem are systematically examined and recommendations on how to eradicate the origin are made considering the ease/cost of implementation vis-a-vis their effectiveness.
A causality chart is made for an overview of important connections.
If you would like to improve coordination, cement production knowledge and skills in structured analysis among plant staff, a CemWise workshop in operational excellence may suit you well.
The workshop combines discussions of observations from daily operation made by plant management and staff with structured root cause analyses and short theoretical lectures explaining relevant underlying processes. At the same time, attention is systematically pointed towards the potential to improve coordination from incorporating lessons learned.
A ready-to-implement action plan for improved performance is the end result of the workshop, where practical issues and issues of prioritization has been dealt with for the purposes of clarification, as well as involvement of the relevant parties.
CemWise follows up on the action plan with a final report elaborating on the issues and solutions in the action plan.
In continuation of our assessments we offer programs of implementation support. The specific content of a program is defined according to the findings of the assessment. A program is typically structured around a schedule of follow-up teleconferences and visits to site. These meetings provide the possibility to discuss unexpected results and clarify questions and they are a strong tool to keep focus and dedication on track.
Remote assistance is an element in the implementation support programs that is also offered as an individual subscription following an assessment. It is provided so that expert knowledge is available and can be turned to whenever an issue of some seriousness occur. It is done in the form of consultations with directions on the elements to investigate, but we can also connect to your control system for a direct overview in order to analyze how an issue is best dealt with.
In a complex process it is not so much the parameters in themselves as it is their relations that are important.
When we monitor the long term developments in operating data and key performance indicators, it is a way for our customers to rest assured that if important parameters begin to slide out of range, we will identify it at an early stage. Measures can then be taken in due time to safeguard stable operation and ensure a long service life of main components.
Planned shut downs are a major tool to invest in maintenance. The cost in terms of lost production is high and each day of a stop has to be weighed against the number of unplanned stoppages that otherwise can be expected. For an efficient shut down in terms of both saved time and safe results, meticulous planning and coordination are required.
We offer our experience in planning with recommendation of inspections to be made in preparation and assistance to ensure spare parts are ordered in time; define the critical path of activities during the stoppage; to make prioritized and detailed job lists, specify contractor requirements and scopes. We also provide project management of the shutdown with coordination and follow-up, controlling of contractors and supervision of the works to ensure an efficient use of time as well as that all resources are utilized to the optimal possible.