Cement & Mining
Cement Plant Process Automation
Complete process automation of a 500 TPD cement grinding unit including raw mill, kiln feed, clinker cooler, and cement mill operations.
Chittorgarh, Rajasthan
500 TPD
Cement & Mining
2023
The Challenge
Problem Statement
Inconsistent clinker quality, high specific energy consumption, and frequent kiln trips due to manual control.
Our Solution
Engineering Approach
Implemented DCS-based centralized control with advanced process controllers, predictive analytics for kiln stability, and energy optimization algorithms.
Impact
Project Results
↓ 15%
Specific Energy
96%
Kiln Availability
+40%
Quality Consistency
50%
Operator Reduction
Technical Details
Specifications
Control SystemABB Symphony Plus DCS
I/O Count2000+ points
Drives18× ABB Medium Voltage VFDs
AnalyzersX-ray fluorescence online
NetworkRedundant fiber ring
Control Rooms2 centralized + 4 local
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