Human free maintenance icr

I

)

: \

1G L---

ffi rffi. i

INNOVATIVE ENCIN EERINC

*i1{{

[* ,,Wa

"rT

30 YEARS OF ICR

Human -free maintenancd Looking into the future and making predictions is always a difficult task. However, in the cement industry there are some strong trends that could point to future demands and restrictions. By the same token there are dramatic developments in general plant manufacturing and the maintenance industries. Together, these trends plus the advances with lndustry 4.0 can help to have an educated glimpse into the Future of Maintenance or

I

by Dr Gary R Heoth, Costolin Eutectic, Switzerland

lement is used to make concrete,

Figure 1: globaI population and cement demand intensity, 2014-50

L,f,.

most consumed manufactured substance on the ptanet. However, the

a f,

cement sector is the third-largest industriaI energy consumer with a seven per cent share in globaI industrial energy use and

a 0

I rzoo c

- 7s00

.E

lltff

eoo

- s000

!

; u0

- 2s00

a00

a

&

r

I

Figure 2: electrical power demand by process

cement grinding 32o/o

CHINA-production

INDIA- production intensity

O utooir fRsr-

production

intensity

0

(AFs) (see Tabte 1).

Wortd demand intensity

intensity E

tff

o

E

-

E

cent below current levels by 2050. Four key routes for reducing CO, have been identified, including improving energy efficiency and switching to atternative fuets

Urban population

o

0o

g

i

I

q)

E

Some regions, such as China and

2014 2020 2025 2030 2035 2040 2045

2050

Source: UN DESA, US Geologicol Survey

. less plant staff: mutti-tasking, younger and less experienced with training as key element . maintaining benchmark operational standards in new, remote [ocations . lower spare parts stock.

lmproving energy efficiency will require focus on grinding operation effectiveness and etectricaI power consumption (Figure a

2). From the these trends and is clear

CO2

targets it

that cement plants of the future will

be focussed on CO, reduction, increased use of AFs and improving plant energy efficiency (etectrical and thermal). ln addition, to support these initiatives there witl also be strong financial demands on ptant operation such as: . maximum ptant avaitabitity: no unplanned downtime or waiting for spare parts detivery . longer operationat campaigns and shorter outages . maximum plant operating performance: as designed by plant OEMs

Tabte

l:

lndustry4.0 and the cement industry There is currently much discussion about lndustry 4.0 and how this wil[ revolutionise the industrial wortd and add USSl4trn to the globat economy. Figures

illustrate its background and essentiaI components.

Today there are 16bn connected devices, or two devices per person, and

3 and 4

this is expected to doubte by 2020. This impties that cement ptant components

key indicators to achieve targets set by the Gtobal Câ‚Źment lndustry Roadmap

Indicator Electricity intensity of cement (kWh/t cement) Alternative fueI use

ICR JULY2OlB

10000

0

the Middle East, have excess cement production capacity, white others, such as lndia and Africa, willincrease cement production capacity to futfit their infrastructure devetopment needs (see Figure 1). Thus, the cement sectorfaces the challenge of meeting an increasing demand for its product while cutting direct CO, emissions from its production.

The gtobat Cement Technotogy Roadmap has an ambitious goatto reduce its direct CO, emissions by 24 per

5

-

1600

0,

0l

infrastructure devetopment.

lo/a

Non-urban population

>c

emissions.

This cement output, and atong with it, the industry's energy use and CO, emissions, is expected to increase further, driven by an increasing gtobaI poputation, intensifying urbanisation and

FuclgrindinS

12500

6

CO-

cement packing and loading

-

2000

o

(0/o

of thermaI energy)

20L4

2030

2040

2050

91

87

B3

79

5.6

t].5

25.7

30.0

I DIGITALISATION

lndustry 4.0 - key buzzwords explained

Figure 3: evolution steps to lndustry 4.0

INTERNET OF THTNGS (roT) Globol network of devices ("Things")

thot can identify themselves, be owore of thei r su rround i ngs, com m u nicote directly with eoch other (vio lnternet) ond even oct outonomously.

.t= P

U

f o

']J o-

t

E xo BIG DATAANALYTICS DEEP LEARNING

-

-

ARTIFICIAL INTELLIGENCE {AI} Process of collecting, orgonising ond

onalysing lorge sets of dato to discover potterns ond other useful information, typicolly performed using specialised softwore tools, which leorn from doto.

@ Bated onthe tnroductlon

of me(hanic.l produ(ion equipmentdilven by waterand {e.m power

llli|llln[rfti Easedon marrproductlon a(htued bydlvlrlon of labor con(â‚Źptand the u*of ele(nkal enerqy Fhst

lom (17&)

prod6$on

llnq Clndnnatl ieughterhoures 0870)

(yb-physi(.1 sFtemslcPPs)

Erst programm.ble logicconkoller (PLC),MdICon O&

EI.\.,

969)

oE

CybeFphyslol

o U

(cPE)

sb{

of 20 6

(stury

acoustic inputs and processing are common measurements in even low-cost smart phones and accessories.

Maintenance 4.0 in the future The demands placed on the maintenance

displays/aterts have dramaticatly dropped.

Location, temperature, motion, vibration,

ele&onr(s and tTto fu(her automrle prdu.tion

Fmfs

and humans could have a similar Level of

for lndustry 4.0 as prices and avaitabitity of key technologies such as sensors, data transfer, data storage, data processing and

IE@EE

8.sd ontheuseot

(1

con nectivity.

ln addition, the conditions are right

@

of cement ptants today are simitar to those of the past and also of the future:

. maximise ptant availability and cement output . minimise energy consumption and unptanned stoppages

.

reduce frequency/duration of ptanned

maintenance outages . reduce maintenance costs (staff, spare parts, repalrs, etc).

However, of particutar relevance today and

fortomorrow are:

.

[imited lifetime of wear parts and reptacement interval not atigned with [onger outage sched u les . new corrosion/wear issues retated to AF use

. monitoring

and predicting when

JULY2OlB ICR

30 YEARS OF

ICR

system to cotlect data using current loT technologies is shown In Figure 6.

Such best-practice transfer is a very efficient toot, but IBM recently hightighted the power of its Watson computer with a cement ptant performance optimisation

Figure 4: elements of lndustry 4.0 Mobile Devices lnternet ofThings Cloud computing

case study based on artificiat intetligence Location detection

Augmented reality / wearebles

technologies

Advan(ed human-ma(hine interfa<es

#e Big data analytica

Continuous direct wear monitoring of key components

Authentications & fraud

Smartsensors

(Al). This approach yietded more advances in problem-sotving over the conventionaI experience/ru [e-based approach. This complete plant digital overview also a[[ows for remote operator training with virtuat reality simulation, which wil[ be increasingty required with more comptex operations in remote locations.

dettrtion

3D printing

White vibration monitoring on drives has a tong history, wear sensors are

a

new devetopment. One system being

devetoped involves direct measurement of the type and rate of wear atong with profite changes over time. These can then be tinked to operating conditlon data.

Wear sensor technology had a big

Figure 5: targets by globaI cement groups Pdud(aprlly ld.x

potential teap with the commercialisation of 3D cameras in smartphones for profile

mapping (Figure 7).

+

+

..a-

Benchmark2ol3

Longer-lasting components of wear parts with a lifetime tailored to plant outage schedules

xxx2013 XXX20I2

XXX = spe(ific Holcim <â&#x201A;Źment plant

Eleculcal En.r9y lndax

As hightighted in Figure 2, increasing the Thermal Energy lndcx

2. Overall performance index

important for cement groups (see Figure 5). This data can atso be used to improve

efficiency of grinding processes is critica[.

New process modelling and simulation software can determine an optimal grinding component design. Real-world data is being added to these modets, which inctude casting and surface defects.

This can also predict operationalfaiture

equipment design by the OEM. An ideat

regimes to be avoided (see Figure 8).

(oPl) chart Holcim

plant is not running optimally and assessing residua[ lifetimes of key wear components . high cost and long delivery time of replacement parts.

With this list of requirements and an understanding of lndustry 4.0, what could the future hotd for the maintenance manager?

Figure 6: sensors, deep learning and communication

,l HJa',

Ptant connectivity and benchmarking to improve local efficiency and design

a !D

n. g Ela a6J-l

f,":E

o

^

\

P

f ']f

rnausrry

sora"

* Ii1*

X

Roal

la$ 03

Ime Anelyti6

Many betieve that lndustry 4.0 wit[ not

rl,,i,,

readity apply to cement, but the first steps were atready taken many years

ffi wrywqffimwrH

ago with condition monitoring of critical

motors/drives and deptoyment of gas sensors throughout the plant to batance combustion and emissions.

With continuous consotidation in the cement industry, benchmarking a plant's operationaI performance and efficiency is

ICR

JULY 2O1B

&..-.r'W i#-=, j

!i;Xr. !;,:r;r

I

S&.iffih$LJii+r*#seffit6

C Big Data

Sensors Machine Learning

I

DIGITALISATION

However, an important factor wit[ be to

Figure 7: direct measurement of wear in VRM with sensors

ensure a reliabte machine operation that

works at this optimaI design for the majority of its working [ife. Here extending the wear life of the components is key. With a wide range of materlals and realtime wear rate data, the wear life of the component can be taitored to the outage campaigns.

Wear is a serious issue as it can atso lead to unplanned downtime. Both are costly consequences in terms of energy, product quality, profit and CO, emissions.

7

Need for advanced wear and corrosion-resistant materials The integration of ceramics and advanced

Weor sensor orroy continuously monitors the VRM weor profile ond iPhone X comero

carbides into metattic-based grinding rollers had a significant impact on the wear life of grinding systems and illustrated the importance of developing novel materials.

The next generation of metallic-ceramicpotymer hybrids are currently being tested

with 3D surfoce mo'pping copobility

in the [aboratory. These inctude diamondcontaining composites that have been used successfutty for years in the mining and oiI exptoration industries to extend the lifeti me and mineral fractu ring efficiency.

The fatting price of industriatdiamonds and integration of diamond composites into [arge-scale industrial processes could provide solutions for the cement industry

Figure 8: stress modelling of roller press

including materiaI defects Coating system

Material

Coating system

Contact Surface

! !

Roller

1

1

Roller 2

(see Figure 9).

Key component production with 3D

printing and [ocal robot-based repair

Figure 9: diamond-containing wearfacing apptied with industrial processes

With the ever-increasing complexity of components and long detivery times for replacements from the OEM, the abitity to create these components tocatly with 3D printing is appeating. Laser-based 3D metaI part printing and ctadding are showing the most promise. Figure 10 illustrates a comptex-shaped transport screw printed in workshop. A worn ba[[ valve is being repaired automaticalty having already had its wear profile 3D scanned, With the reduction in the price of robots a smatt

201AtO5D5

H

MUD'13.0

x30

2 mm

Figure 10: laser 3D coating and printing of wear components

and laser systems construction, local repair and coating of criticaI wear and corrosion components is now possibte, and on-site laser cladding is a proven technology in other industries.

Conclusions The etements of wear monitoring, newwear and corrosion-resistant materials, advanced wear modetting and new

maintenance technologies wi[[ ptay a cruciaI role in achieving future cement industry goats while wholeheartedty embracing the Maintenance 4.0 phitosophy.

I JULY 2018