Eng° Eduardo Champs

Cemengal L.A. Ltda.

“TECNOLOGY UPGRADES ON CEMENT INDUSTRY: WHAT MAKES THE DIFFERENCE”

SYNOPSIS:

This presentation will walk the spectator towards the most innovative technologies
available for cement production analysis available.

Cemengal´s conceptual and cutting edge engineering is always thinking ahead its time, and
that is why our brand can offer solutions for every portion of the production line, focused on
energy saving, reduction of maintenance as a result of maximizing the availability of the
installed capacity.

This brief presentation will analyze how the cost of the finished product may be affected by
poor performance, improper operation, inappropriate design and no domain or knowledge of
the production process.

A very interesting and mainly used way to identify potential maintenance problems,
availability of operation, applicability of the solutions adopted, the profitability of projects
implemented to increase the production potential and gargles on the production line is the
construction of the tree of process indicators, which will be shown in the chart below:

CEMENGAL L.A. IMPORTAÇÃO E EXPORTAÇÃO LTDA

R. Casa do Ator, 1117 9°Andar – Vila Olímpia – São Paulo – SP – Brasil
Fone: +55 11 3044.4125 /Fax: +55 11 3044.4632
CEP. 04546-004
 Eng° Eduardo Champs
Cemengal L.A. Ltda.

That is:

 The low load factor can be caused by full silo, and it´s indicate that it cannot be a
problem in the installed equipment, but an external factor of low market activity. (this
is the only indicator that should be examined individually, due to its susceptible
interference not inherent in the production process.

 With this indicator we can analyze whether there is a systemic problem in the
equipment, either individually or in the context of the production chain.

 The statement of best practices should be identified very carefully, because we can
not only choose the best practices of the market, we have to analyze the best
practices in similar process conditions to those applicable at the installed capacity
analyzed .

CEMENGAL L.A. IMPORTAÇÃO E EXPORTAÇÃO LTDA

R. Casa do Ator, 1117 9°Andar – Vila Olímpia – São Paulo – SP – Brasil
Fone: +55 11 3044.4125 /Fax: +55 11 3044.4632
CEP. 04546-004
 Eng° Eduardo Champs
Cemengal L.A. Ltda.

The chart shown above evaluates the performance of the equipment with concerning to the
complete production chain, thus making an analysis not only individually but as part of a
productive organization, where all features are related to their equipment, so the symptom of
malfunction in a given area may have their initial reasons found in another moment of the
production line, this occurs because the energy involved in the process, the gas flow, the
mass balance and thermal balance of the process has begin and end within the production
cycle.

To illustrate, following I will give an example of how different stages of the production cycle
can be affected by its predecessors and/or successors steps.

e.g.:

1- When a Bag Filter has over saturated bags, it increases the pressure drop thus
increasing the absorbed power at the impeller motor.

2- When any conveyor device has bad lubrication, it consequently increases the friction
coefficient thus increasing also the absorbed power at the gear motors.

Above, we can see symptomatic problems with isolated equipments, but if we consider the
sum of the incensement of absorbed power looking at the installation it will have a
enormous impact on the final cost of the product, due to the high representation of
electrical energy in the cost composition of cement.

3- When the mills works with low levels of homogeneity impacts in low productivity, and
high levels of reprocessing material, causing poor efficiency of dynamic separator
and overload of the process bag filter, but the cause didn´t have its origin at the
mentioned equipment but at the mill.

In this case shown above, the problem in one equipment cause a problem in the system,
when looking in the indicators tree, but due to that we have to analyze to the system, when
the problem is identified, with the individual tools.

With this kind of analysis it’s possible to adjust the equipment to the process properly,
avoiding gargles, inefficient equipments, energy waste, fatigue, high wear and
consumption, making the process more efficient and greater longevity of parts and
components, and also decreasing the cost of operational maintenance.

CEMENGAL L.A. IMPORTAÇÃO E EXPORTAÇÃO LTDA

R. Casa do Ator, 1117 9°Andar – Vila Olímpia – São Paulo – SP – Brasil
Fone: +55 11 3044.4125 /Fax: +55 11 3044.4632
CEP. 04546-004