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Siemens supplies drive systemsfor two gold mills

Siemens project partner FLSmidth was commissionedby Canadian gold producer B2Gold at the end of 2015to supply two mills for grinding the ore in its new plantin Mali. FLSmidth will be supplying a semi-autogenousgrinding (SAG) mill as well as a ball mill. Both mills willbe equipped with Siemens Integrated Drive Systems thatwill help B2Gold reduce its capital investment and saveup to 50% on spare parts.

By using converter technology for regulating therated speed of the SAG mill motors so that the four largeFlender gears all work with the same transmission ratio,both mill types can operate with the same gear size anddesign. This reduces capital investment for the mechan-ical drives by 17%and spare parts costsby up to 50%.

The SAG mill is drivenby two 7,500-kW, air-cooled asynchronousmotors from theSimotics HV series;oil-filled drive isolationtransformers; and twowater-cooled SinamicsGM150 frequencyconverters. For thedual-pinion ball mill,Siemens USA is supply-ing two 5,250-kWslip-ring motors,liquid starters, andthe frozen chargeprotection package. The gears, couplings, and lubri-cation units for the two mills will be supplied bySiemens Flender in Illinois. The frozen charge protec-tion function developed by Siemens protects millsduring start-up by ensuring that the charge that hasbecome firmly attached to the mill wall does not detachrapidly and damage the mill. Different operating modesof the mills, such as controlled ramp-up, load balanc-ing, creeping, and inching, all serve to reduce the loadon the mechanical components, significantly extendingthe service life and preventing damage. Additionally,a controlled load balancing function is provided to helpminimize mill downtime.

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thyssenkrupp Industrial Solutions and Siemens haveextended their successful collaboration for miningconveying system solutions for another five years,which ensures that the mining industry will continueto profit from innovative and reliable transport sys-tems and solutions.

The mining industry is faced with falling gradesand new mines in remote locations, both leading to theneed to transport more material over longer distances.“Conveying technology must keep up with the com-plex requirements of the modern mining industry. Wewant to continue offering our customers reliable andhighly-efficient conveyor systems,” says Jens MichaelWegmann, Chairman of the Management Board of theIndustrial Solutions business area of thyssenkrupp.“It is only possible to optimize modern mechatronicbelt drive systems like this by working in close colla-boration with a partner because the mechanics andthe motor form a self-contained unit. That’s why weare continuing the tried and tested collaboration withSiemens,” Wegmann continues.

In mining, robust, reliable, and easy-maintenancedrive technology is a key component of conveyor sys-tems. “We are happy to be able to keep on supportingthyssenkrupp with our well-proven direct drive sys-tems featuring Sinamics cycloconverters and ruggedsynchronous motors that have undergone continuousdevelopment in recent years,” says Jürgen Brandes,CEO, Siemens Process Industries and Drives. Both

Together with the well-established engineeringservice provider and Siemens Solution Partner CESACement Engineering SA, renowned for excellence inengineering and consultancy services for industrial,mining, and cement plant projects, from feasibility

studies to commissioning to start-up, Siemens hasrecently successfully implemented several inter-national cement projects, meeting tight schedulesand overcoming challenging conditions.

One particular project to benefit from the smoothcooperation between Siemens and CESA is NOCIBE,owned by Les Ciments du Sahel, currently the largestcement plant in Benin. But CESA and Siemens alsocollaborated on a new CMS Cement plant in Kuching,Malaysia, and a new cement factory for Germany’sSchwenk Group in Ohorongo, Namibia. In every caseCESA served as a very reliable consultant and engi-neering services provider to the end customer, andSiemens is looking forward to future projects withCESA Cement Engineering.

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thyssenkrupp and Siemens have many years of experi-ence in mining and lead the sector in their respectivetechnological fields. The two companies have success-fully implemented a number of joint projects in recentyears. thyssenkrupp provided the conveyor systemfor Xstrata Copper in the Antapaccay and Las Bambascopper mines in Peru, for example. And Siemensprovided thyssenkrupp with the direct drive forthe world’s largest conveyor belt. The belt conveyorsystem is being erected in the Peruvian Cuajonemine belonging to the Mexican Southern CopperCorporation mining company.

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he main elements of com-petitiveness are productivityand operational excellence.

This reality has not changed overthe centuries. What has changed,however, are the possibilities mod-ern technology offers – especiallyto those who are open to rethink-ing the entire mining process. Inthis context, digitalization playsa crucial role.

8C*AI=!DEI^ *Z.*^^*E.* =D,IXIn the past, enhancing operationalexcellence in the mining industryoften meant nothing more thansimply cutting costs. But now, mod-ern technology is opening up newways to achieve breakthroughs inproductivity. Leading mining com-panies all over the world are con-tinually investing in state-of-the-art automation, energy, and drill-

T ing systems in order to increasemining intensity with lower per-sonnel and energy costs. Somecompanies are able to achieveenergy savings of 10% to 40%through renewable energy instal-lations, innovative energy tech-nologies, and highly automatedmining processes.

Advanced distributed controlsystems (DCSs), such as SimaticPCS 7, are critical here. The open,flexible, and scalable architectureof PCS 7 ensures maximum pro-ductivity and reliability. Thanks toits integration with safety, indus-trial security, and energy man-agement systems, it helps protectpersonnel, machinery, and theenvironment – and lays the foun-dation for the digital enterprise.Its integrated Advanced ProcessLibrary (APL) provides the best

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route to higher efficiency in opera-tion and engineering. In addition,Siemens has released the MineralsAutomation Standard, a tailor-made solution that is designed tomeet all mining requirements andthat ensures the highest levels ofefficiency and reliability.

8E =AI.` =D ?;CCDA= =#* (;=;A**E*A%X F!ZAs the global energy mix shifts andtechnology advances, companies inthe mining sector can benefit fromemerging opportunities to controltheir energy costs. The sector’s best

partner in pursuing these op-portunities is Siemens – for exam-ple, through the substitution ofthermal coal with renewables,or through the identification ofenergy savings potential withSimatic B.Data. This holistic andproven state-of-the-art energymanagement solution covers allrelevant business areas, from pur-chasing to controlling, and therebyensures efficient energy and costcontrolling. Innovative Siemenssolutions also contribute to maxi-mum vehicle operating efficiency,which minimizes the cost per ton

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of hauled material by improvingoverall system efficiency andreducing maintenance. A goodexample of this technology is anonboard energy storage systemthat allows for the reuse of storedregenerative energy at low-effi-ciency operating points. Thissignificantly reduces emissions.

:A!9*E =D C*A(DAFImplementing innovations in themining industry always demandsa certain degree of openness, asinnovation goes hand in hand witha change in tradition and culture.Today it is no longer enough tooptimize existing equipment andpossibly outdated technology.Any mining company striving forbetter and more economical ex-traction must embrace innovation.Many of today’s game-changingtechnologies are highly automatedor even entirely autonomous. Thespectrum includes robotic andGPS-supported mining systems, aswell as autonomous rail systems,among others. With its expertise in

Some companies are able to achieveenergy savings of

10% to 40%through renewable energy installations,innovative energy technologies, andhighly automated mining processes.

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automation and robotics, Siemenscan help deploy these technologiesin mining.

Another innovation issue thatmust be addressed is improvingasset management so that it canhelp mining companies look pasttomorrow. Enhanced asset manage-ment is key for the implementationof smart repair and maintenancestrategies – and therefore contrib-utes to maximum availability andproductivity with minimum effort.Among the most valuable assets inthe mining industry are the drivesystems. They must meet ever ris-ing demands in extraction, trans-portation, and beneficiation. Gear-

less drives; perfect interaction be-tween sensors, IT, and mechanics;and intelligent service strategiesare key here – and with Siemens,mining companies always benefitfrom cutting-edge technology.Siemens offers the world’s firsttrue one-stop solution for entiredrivetrains, setting new standardswith Integrated Drive Systems (IDS).IDS ensure perfect interaction of allcomponents, reduced engineeringeffort, maximum investment secu-rity, and lower operating costs.

Digitalization also paves the wayfor enhanced efficiency in employ-ees’ daily routines by providing theright information to the right per-

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son at the right time. With itsunified data platform, the Comosengineering and collaboration soft-ware provides all involved partieswith a continuous flow of data thatmeets their specific needs acrossall project phases.

:I=IK Q!E!E%K UE,;?=A!* )KHWith global trends such as digitali-zation and Industrie 4.0 becomingmore and more relevant to themining industry, companies needsolutions that not only collect andvisualize operational data but alsomanage them across differentsites. The good news is that today’ssystems already offer most of thefunctionality that is needed: theymake it possible to share valuableexperience and insights withother sites via a seamless datatransfer – and thereby not onlyhelp solve problems but also allowfor company-wide process andplant performance comparisonand optimization.

Innovative Siemenssolutions also contributeto maximum vehicleoperating efficiency,which minimizes thecost per ton of hauledmaterial by improvingoverall systemefficiency and reducingmaintenance.

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direct conveyor drive systemcomprises a low-speed syn-chronous motor, a cyclocon-

verter or voltage source converter,drive control, power distribution,an E-House, and a cooling system.Eliminating various components ofthe drivetrain reduces maintenanceeffort and spare parts inventoriesand allows the system to offer uni-quely high availability. Even in chal-lenging applications, direct con-veyor drives can achieve a bench-mark availability of more than 99%– as confirmed by real-world datafrom the Antapaccay mine in Peru.There, the belt system transportsapproximately 5,260 tons of oreper hour from the mine to the pro-cessing plant over a distance ofaround 6.5 km. The Siemens drivesystem for the belt conveyor con-sists of two low-speed synchronousmotors, each with a power ratingof 3,800 kW, and the associatedSinamics SL150 cycloconverters,E-House, cooling system, and con-vertor transformers.

2A!C^* .#I^^*E%*In 2015, Siemens commissioned di-rect conveyor drive systems for twoadditional copper mines. One wasfor one of the largest copper minesin the world, which is located inChile (5 x 5,000 kW). For the over-

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land conveyor provided by thyssen-krupp with a length of more than10 km, Siemens supplied five directdrive systems (for a total of fourconveyors) with the largest con-veyor motors in operation at pres-ent.

The overland conveyors at LasBambas copper mine in Peru weredesigned and supplied by thyssen-krupp and have been in operationsince the fall of 2015. Each of thetwo overland conveyors is approxi-mately 2.5 km long with a lift ofalmost 300 m and transports orefrom the mine to the processingplant. The belts are 1,830 mm wide,travel at 6.5 m per second, andare designed to transport approxi-mately 9,400 tons of material perhour. The stockpile at the end ofthe conveyor system is more than50 m high and can supply the pro-cessing plant with up to three days’worth of copper ore for processing.The drive system for each of thetwo overland conveyors comprisestwo low-speed synchronousmotors – each with a total powerof 4,400 kW – and the associatedSinamics SL150 cycloconverters.

3FDD=# *Z*.;=!DE IE, ?=IA=M;CThe overland conveyors at LasBambas were commissioned veryquickly and the conveyor system isnow in operation. “The project hasbeen very successful and we arerunning the conveyors at nominalcapacity with few issues. The gear-

less drives are beneficial from aservice point of view, given thatthere are no motor bearings orgearboxes, which simplifies ongo-ing maintenance requirements,”says Timothy Mess, project direc-tor at thyssenkrupp. Peter Mizera,MMG’s general manager for LasBambas project delivery, sharesthis positive view of the projectoutcome: “Las Bambas has beena great success, and Siemens wasa large contributor to this outcome.Siemens provided solid supportduring construction, precommis-sioning, and commissioning, andas a result we were able to completethe overland conveyor commis-sioning very quickly – in just undertwo months. This was a fantasticachievement.”

P*Z= CADb*.= DE =AI.`Following Las Bambas, Siemensrecently supplied the world’s high-est-powered direct conveyor drivesystem to the Cuajone mine inPeru. The modernization projectwill entail the installation of a newgyratory crushing and conveyorsystem from thyssenkrupp by 2016.Siemens proposed an IntegratedDrive System with direct conveyordrives to power this conveyor sys-tem, which has an output totaling12,000 kW.

The conveyor belt system com-prises three individual sectionsthat are equipped with a total offive Integrated Drive Systems. For

the largest of the belt sections,Siemens is supplying two drive sys-tems with an output of 6,000 kWeach, comprising a low-speed syn-chronous motor and a SinamicsSL150 cycloconverter. The twosmaller feed and discharge beltswill be driven by two 500-kW low-voltage motors using SinamicsS150 converters with regenera-tive feedback capability and one1,200-kW medium-voltage motor.The converters and motors as wellas the gearboxes and couplingsfor these drives are all supplied bySiemens. The automation compo-nents and the drive and powerdistribution technology are pro-vided in modular electrical rooms(E-Houses). Over the years Siemenshas improved and optimized thecooling system, the modular de-sign of the E-Houses, the powerdistribution, and the automationand drive control so that they areperfectly aligned with the miningindustry’s specific requirements.

At Cuajone, Siemens will con-tinue the company’s impressivetrack record of successful projectsin South America – and reinforceits position as one of the leadingsuppliers of electrical and automa-tion systems for the global miningindustry.

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The battery systems consist ofstandardized modules encasedin robust, specially designedhousings.

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typical mining facility uses off-road miningtrucks to haul materials such as coal, ore, andoverburden from the pit to a stockpile where

the material can be stored or processed. A conventionalhaul truck operates with a diesel engine, which addsconsiderable fuel expense to the entire mining opera-tion.

The main objective of haul trucks is to achieve thelowest cost per ton of hauled material, which meansthat improving overall system efficiency and reducingmaintenance for any given payload is critical. Oneway to improve efficiency is to fit the truck with anonboard energy storage system. These systems storeregenerative energy and reuse it at low-efficiencyoperating points, thereby reducing fuel consumption,decreasing emissions, and increasing profitability.

8CCDA=;E!=X (DA !FCAD9*F*E=Use of diesel-electric trucks for payloads of morethan 200 tons has been on the rise in recent years.And among diesel-electric trucks, the trend has beenmoving toward AC drive technology. Although signi-ficant improvements have been made to electric driveand control technology, the use of energy storage sys-tems is practically nonexistent in trucks, resulting ina lost opportunity to improve fuel economy throughregenerative braking and engine-idle operation.

Mining trucks have onboard diesel engines thatserve as their fixed source of power. Because theseengines have parasitic losses and other auxiliaryloads, not all of the engine capacity is available forpropulsion. This is where energy storage comes intoplay. A suitably configured energy storage systemcan store a portion of the regenerative energy andfeed the auxiliary systems, making 100% of the enginecapacity available for propulsion without consumingadditional fuel. The speed of a truck is directly pro-portional to the available power; hence, if the energystorage could provide 10% additional power, thespeed of the truck would increase by 10% – resultingin reduced cycle time and increased productivity.

89*A.DF!E% =#* .#I^^*E%*?Mines present a unique set of challenges when itcomes to the selection of suitable energy storage de-vices, as they are often located in remote locations

with extreme climatic conditions. In addition, miningtrucks are subjected to extreme shocks and vibrationsduring operation, which means that any energy sto-rage device would need to operate reliably under theseconditions. Batteries offer excellent energy storagepotential. Their high energy density makes them wellsuited to delivering power for longer durations. Ad-vances in lithium-ion-based high-performance batterysystems have made it possible for these systems to beused in a wide range of applications for public trans-port, commercial vehicles, and stationary storage sys-tems, among others.

The space on the truck deck is limited, and hencesystem integration is very important. The modularconfiguration of the lithium-ion batteries allows themto be adapted to any load profile and type of installa-tion. The battery systems consist of standardizedmodules encased in robust, specially designed hous-ings. The battery-management system incorporatedinto these modules constantly monitors cell voltagesand temperatures while balancing differences inpotential. Communication takes place via a smartcontroller area network (CAN) interface. The batterysystems offer high cycle stability and outstandingprotection against thermal runaway, and their highefficiency and low maintenance translate into avery favorable cost/benefit ratio for mining opera-tions. In addition, the systems are designed to beboth intrinsically safe and environmentally friendly.

UE.A*I?*, *(O.!*E.XN CAD,;.=!9!=XNIE, ?;?=I!EIG!^!=XReducing fuel consumption in hauling trucksthrough the implementation of onboard energystorage systems from Siemens can have a significantimpact on the efficiency, productivity, and sustain-ability of mining operations. This ultimately resultsnot only in higher profits for the mining industry,but also in a cleaner and safer environment for localcommunities.

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mproving productivityof open-cast operation hasbeen and will always be

a challenge. The quality of the orebody continues to deteriorate andtherefore more ore needs to betransported in the most economi-cal way to optimize productivity.The aim is to lower the cost per tonof transported ore and improvethe environmental footprint.

Typically, uncrushed ore is trans-ported by trucks, which oftenleads to congestion on busy roadstretches. The trucks usuallytravel fully loaded with ore oneway to the dump or to the crusherstation outside the mine andtravel back to the pit empty. Andthe process repeats itself. Thecycle can easily take up morethan 30–40 minutes, dependingon the depth of the pit.

In order to optimize the truckutilization, to reduce the fuelconsumption, and to increasethe productivity of the mine,a new transportation system,the Chevron MegaPipe conveyorhas been developed.

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Pit perfect!

ContiTech, Siemens, and thyssen-krupp, in a joint research anddevelopment consortium, havedeveloped a solution that canreduce this heavy-duty trafficand the associated emissions andrisks: the Chevron MegaPipe con-veyor. This new continuous con-veyor for bulk materials requiresjust one primary crushing stagein the feeding station area andsets new standards in terms ofascent capability and transportcapacity.

The new conveyor is a further de-velopment of traditional conveyorsystems, which are already beingused instead of trucks in extensiveopen-pit mines with general slopeangles of under 30°. The conveyorsystem consists of a tubular beltwith profiled cover plates on thecarrying side. When the MegaPipeis rolled up from a troughed forminto a tubular form in the materialfeeding area, the material in thepipe is “compressed,” which wedgesthe product particles together andthus increases the internal frictioncoefficient of the bulk materials.This compression, together with

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the special profiling on the belt,enables the economical transportof large material flows over slopeswith moderate incline angles andopen-pit mine depths of severalhundred meters, right after theprimary crushing stage.

:!A*.= ,A!9* (DA #!%# C*A(DAFIE.*The drive technology is anotherkey component of the new con-veyor system. About five years ago,Siemens and thyssenkrupp devel-oped a direct drive for powerfulconventional belt conveyors basedon the also jointly developed Band-berg Prosper, a 3.8 km-long under-

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ground conveyor system risingapproximately 800 meters, in-stalled at RAG Prosper-Haniel in1985. Thanks to the simple androbust mechanical design, inte-grated drive drums, and a directdrive motor in combination withcutting-edge converter technology,as well as the proven control sys-tem, the drive solution allows largebelt conveyor systems to be oper-ated economically. The completedrivetrain, consisting of a flangefor the disc brake, drum/motorbearings, and a rotor flange withrotor and stand, was designed touse just a few robust components

that can be integrated into the beltconveyor station in a space-saving,maintenance-friendly way.

PDE?=DC G*E*O=?The consortium has now alsoinvestigated the feasibility of theMegaPipe concept and has con-firmed that the conveyor systemcan economically transport oresand waste material with grain sizesof up to 350 mm over slopes withinclines of 30° to approximately 50°.

Alternative conveyor systems likethe Chevron MegaPipe conveyor arebecoming increasingly attractive in

view of the fact that in many minesaround the world the ore contentis diminishing, and thus an in-creasing amount of material needsto be transported. These systemsalso help mine operators overcomethe logistic challenges of extract-ing raw materials in an environ-mentally friendly, efficient, andsafe manner.

A viable alternative to shovel/truckoperation in open-pit mining: TheMegaPipe system can transport materialwith grain sizes of up to 350 mmover steep slopes from 30° to 50° andover several hundred meters.

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arsh environments, rising energy costs, andwater scarcity are just a few of the challengesfacing the world’s mines. Kalumbila Minerals

was not only confronted by these challenges but alsohad more to grapple with when building two minesin an isolated area 150 kilometers west of Solwezi,Zambia.

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The region had practically no infrastructure fortransportation or energy supply, and no workforcewith the skills to build one. The local populationworked in farming and ranching and had no experi-ence with large construction projects. But havingcommitted to source at least half of its workers locally,Kalumbila Minerals needed to find and train at least4,000 people to lay roads, weld pipes, erect pylons,and even construct a new airstrip. A further challengewas Kalumbila Minerals’ ambitious production tar-gets: 300,000 tons of copper and 38,000 tons of nickelconcentrate per year within the first six years ofoperation. Meeting this output target would demandadvanced drive technology that could power all themining machinery around the clock with minimaldowntime.

To overcome the challenges and make the projecta success, Kalumbila Minerals recognized the need fora partner that could offer a comprehensive solutionfor both training new workers and providing high-performance integrated drives. End-to-end processoptimization was the only way the company couldhope to overcome its production challenges whileminimizing operational and extraction costs.

“For projects involving limited local skills andcomplex equipment, what we look for in a technol-ogy provider is a robust product and a skilled teamwith the ability to transfer knowledge to our localexpert teams,” says Nevin Scagliotta, commission-ing manager for First Quantum Minerals ProjectsDivision. “With mills of this size, reliable andhigh-efficiency drives are top priority and crucialto project economics.”

:A!9!E% A*.A;!=F*E= IE, CD\*AAs a technological leader in the global miningindustry, Siemens was the obvious choice to providethe advanced drive technology that would giveKalumbila Minerals the power and the cost optimiza-tion it needed. With its experience in implementingand managing large-scale mining projects all overthe world, Siemens also knew what steps to take tosuccessfully source and train the new workforce.

To fulfill its commitment of hiring 50% local staff,Kalumbila Minerals recruited 4,000 workers fromthe surrounding towns and hired 4,000 indirectlythrough on-site contractors. Siemens’ project team,comprising professional engineers, seasoned assem-bly supervisors, and on-site start-up engineers, thentransferred its expert knowledge to the local teams

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so the mine could be running productively in theshortest possible time.

4;%%*, CD\*A IE, .^D?* .DE=AD^With projects of this size, it is advantageous to re-duce the number of supplier interfaces, and thus tohave the entire drivetrain supplied by a single source.Integrated Drive Systems from Siemens offer the onlytrue one-stop solution for drive systems worldwide.

To power the extraction of 300,000 tons of copperand 38,000 tons of nickel concentrate per year, Siemensprovided the motor and drive systems for two 40-footsemi-autogenous grinding (SAG) mills powered by28-MW gearless mill drives (GMDs) and two 28-football mills powered by 22-MW GMDs.

Among the world’s big-gest and most powerfuldrives, the integrated GMDsfrom Siemens provideKalumbila Minerals withthe end-to-end process opti-mization essential to maxi-mize efficiency and mini-mize cost. The drives alsoprovide outstanding reli-ability due to the advan-tages of the gearless design.With no moving gears,there is no variance in themotor and no vibration.This vastly reduces energyloss, as all the force istransferred touch free viathe magnetic field. The lackof moving parts also vir-tually eliminates wear andtear and the risk of down-time. In the event thatmaintenance is required,the drives maintain highavailability thanks to theirdedicated maintenancemodes, such as creeping orinching with rollback of themill.

“Torque and speed control, and especially thefrozen charge protection keep the mill operating inthe safe range, minimize downtime, and keep pro-duction high,” says Axel Fuchs, project manager atSiemens Process Industries and Drives. “The SiemensGMD offers 28 MW and a 150% overload – no otherdrive is able to do that at 9.1 rpm.”

The integrated drive train came along with SimaticPCS 7 and Sinamics SL150 cycloconverter technology.The Simatic PCS 7 controller for the mill drive andKalumbila Minerals’ existing distributed control sys-tem could be seamlessly integrated thanks to theircommon platform, while the rugged Sinamics SL150offers exceptional overload capacity and high effi-ciency through direct energy transformation, which

results in availability ofmore than 99.5%.

@ CAD9*E F!E!E% CIA=E*ASiemens proved itself tobe a trusted partner withthe provision of a qualityservice. This included theprofessionalism with whichits team managed the proj-ect and the engineeringexpertise demonstrated byits gearless drive technol-ogy. Ultimately, Siemens’know-how and experiencewere successful in helpingKalumbila Minerals in-crease the productivity ofits mines while reducingcosts, demonstrating why

Siemens continues to be regarded as the partner ofchoice for the world’s global mines.

“For a critical and complex piece of equipmentlike the mill drives, it is vital to have a self-managingand professional vendor. This is what Siemens hasprovided with its gearless mill drives and the commis-sioning team,” says Nevin Scagliotta of First QuantumMinerals.

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IncreasingIncreasing throughputthroughputthethe smartsmart wayway

fter years of operationin mining processes, millsoften require higher

throughput from the gearless milldrive (GMD) or even the entireconcentrator. This in turn demandsmore power. Siemens has devel-oped a structured study to analyzewhether a power increase is feasibleon preinstalled GMDs.

A power upgrade could be re-quired, for example, if the rockhardness increases as a result ofexcavating at deeper levels, caus-ing the throughput of the grindingmill to decrease. To keep thethroughput constant, the powerof the GMD needs to be increased.

Power can be increased by modi-fying the motor voltage or the cur-

rent, or a combination of the two.Every solution has specific con-

siderations in terms of costsfor replacement parts andimplementation time. Toaccurately evaluate allthe options, detailedknowledge is requiredregarding the GMD sys-tem (especially its mostimportant parts – themotor itself, the trans-formers, and the cyclo-converter) and the rela-tionship between thedifferent variables.

The mechanical calcu-lation for the motor liesat the core of the analysis:

if the design of the motordoes not support the power increase,the required power level cannotbe achieved – not least becausestrengthening the motor structureon-site is complex and uneconomi-

cal. The mechanical study is basedon the finite element (FE) modelof the motor (see illustration) anddifferent load cases. Once themechanical study is complete andindicates sufficient reserves, allthe other components of the GMDsystem must then be verified.

The Siemens study structuresthe engineering process in consec-utive steps to determine the newpower level, with each step build-ing on the results of the previousone. If a step is not completedsuccessfully, the next one cannotbegin, and the study must be re-started using a different technicalsolution or a lower power level.

@ A*\IA,!E% !E9*?=F*E=Together with the analysis report,Siemens provides a price indica-tion for the necessary new equip-ment, as well as a draft shutdownand sequence plan for the imple-mentation – all the informationneeded by the customer to evalu-ate whether the project offers asatisfactory return on investment(ROI).

Based on the experience ofrecently implemented power in-crease projects, the power leveltypically increases by approxi-mately 10% to 15%, and the ROIcan be achieved within one yearor less. The combination of thecomparatively low investment andshort implementation time for theGMD systems offers clear advan-tages for the mining industry.

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he two dual-pinion mill drives for two new24' × 40 ' ball mills, each with 2 × 6.5 MW(2 × 8,700 hp) power, are the first two mill drive

systems using slow-speed squirrel-cage inductionmotors with cycloconverter technology in grindingmills, and they combine the benefits of both systems.Cycloconverters are well proven in mining, especiallyfor ring motor (wraparound motor) applications. Theyare perfectly suited for mill drive applications due tothe low-frequency drive, the robustness and efficiencyof the thyristor technology, and the low number of se-miconductors. Consequently, the solution designed bySiemens features the highly reliable components andhigh system robustness required by the application.

UE=*%AI=*, ?D^;=!DE (DA FIZ!F;F *(O.!*E.XThe Siemens scope of delivery included the inductionmotors and the cycloconverters for variable-speeddrive operation with the corresponding insulatingtransformers, as well as premanufactured E-Housesand 13.8-kV switchgear, perfectly coordinated with thedrive, and the complete harmonic study. The water-cooled, compact, and totally enclosed IP55 motorswere shipped fully factory-tested in one piece. Themotors have a nominal speed of 180 rpm and a torqueof 345 kNm and are equipped with sleeve bearings,including a jacking unit. The motor shaft is directlycoupled to the pinion via a torque-limited coupling.The cycloconverter is an air-cooled Sinamics SL150with a power rating of 8 MVA. For smooth operationof the two motors on a dual-pinion drive system, theyare equipped with a controller that provides accurateload sharing under all working conditions. The milltechnology control package also includes smoothstart-stop operation modes, creeping mode for main-tenance, and inching mode for positioning the mill incase of liner exchange, as well as the required frozencharge protection. The drive system is designed for anoverload capability of 150% during the mill start-upand 115% continuously (1.15 service factor). The oil-cooled insulation transformers are sized accordingto the mill drives’ requirements. To minimize instal-lation and commissioning time, the air-cooled driveswere installed and precommissioned by Siemens,including the 13.8-kV circuit breakers, in a new con-tainerized E-House.

4!?!E% =D =#* .#I^^*E%*The customer received a perfectly tuned drive systemfrom a single source. The solution is the most robust,reliable, and energy-efficient option currently avail-able on the market. Over the first year of commercialoperation, it has demonstrated excellent reliabilityand performance, even running occasionally at over-rated capacity, and incurring minimal maintenancecosts.

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ickel mining companieshave been achieving signi-ficant gains in both pro-

ductivity and efficiency in recentyears by improving the operationof conveying and crushing systemsthrough automation. In a typicalconfiguration, nickel ore is loadedonto a conveyor belt, where it is uni-formly distributed by a profilinggate located at the infeed. After trav-eling on the belt, the nickel is dis-charged into a surge hopper abovethe jaws of a crusher. The efficiencyof the crusher depends on a consis-tent flow of material being fed intoit – which in turn requires a moni-toring system capable of quicklyand accurately identifying processupsets.

QDE!=DA!E% .A!=!.I^ =D CAD.*??C*A(DAFIE.*When it comes to nickel production,the automation of conveying andcrushing systems presents a num-ber of challenges. First, monitoringinstrumentation must be able toreliably determine the amount ofmaterial on the conveyor belt so asto establish a flow rate that is opti-mal for operation of the crusher.

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Most importantly, the measuringdevices need to be able to work to-gether effectively to communicatethese situations to the control roomso that appropriate action can betaken and process upsets can beprevented.

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speed sensor, and a MilltronicsBW500 integrator. This solutiondelivers instantaneous measure-ment to ensure that raw materialis conveyed from the infeed intothe crusher at a variable rate thatis based on the level of material inthe crusher. The second systemneeded is for level measurement inthe crusher. The best option in thiscase is a noncontacting device suchas the Echomax XPS15 transducermounted in the open air abovethe bin and connected to an ultra-sonic level controller, for example,a Sitrans LUT420 device.

:*=I!^*, CAD.*?? ,I=I #*^C DC=!F!V*.DE=AD^With this configuration of Siemensequipment, nickel plant installa-tions have two systems that work

together with high and low alarmson both the crusher bin and theconveyor belt. The milliampereoutput of the Sitrans LUT420 actsas an analog input into the variable-frequency drive of the conveyorto control its belt speed so thatwhen the level of raw materialdrops in the crusher hopper, thebelt speeds up. When the level getstoo high, the belt slows down.

Additionally, the onboard relaysof the Sitrans LUT420 make it pos-sible for high and low set points toactivate an alarm to ensure thatmaintenance crews perform visualinspection and diagnose any prob-lems. Similarly, the milliampereoutput of the Milltronics BW500can monitor flow rate, as the unithas onboard relays for load-basedhigh and low set points – allowing

proper action to be taken in theevent of feed starvation on theconveyor.

UE=*%AI=!DE ^*I,? =D #!%#*A*(O.!*E.X IE, I,,!=!DEI^ ?I9!E%?With an integrated solution for thecrusher application, a nickel pro-ducer can come full circle in termsof plant automation. This circlebegins with the removal of manualoperator intervention, resultingin safer practices, improved plantefficiency, and reduced mainte-nance costs. The money saved canthen be invested into further plantautomation.

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emtec – Cement and MiningTechnology GmbH, an Aus-trian family-run company

with some 240 employees and nowmanaged by the second generationof the family – plans, develops, andexecutes projects for the cementand processing industry worldwide.One of its latest projects is the de-livery of a mill system to Russia,where, following initial start-up in2014, two gigantic mills processup to 30,000 tons of ore every dayto extract gold. In only 10 months’construction time, Cemtec, togetherwith the drive specialist Siemens,developed and built a completesolution – one that is unique interms of its size, performance, andspeed of implementation.

W!%#MC*A(DAFIE.* =*.#ED^D%XTwo mills are used to grind upthe ore: a semi-autogenous millmeasuring 10.4 m x 6.1 m with adrive output of 15 MW, and a ballmill with a drive output of 18 MW.The first mill grinds down lumpsof rock with a maximum size of250 mm (F80 = 152 mm) to 2 mm,and the second then grinds these2 mm grains (F80 = 1,000 µm) downto particles as small as 74 µm. Onlythen can flotation take place to ex-tract the gold. The ball mill mea-sures 8.2 m x 14 m, and in terms ofits power, which is transmitted me-chanically by means of gear units,it is one of the world’s largest hori-zontal mills, if not the largest. Itis driven by two 1RR5108-6FA90-Zthree-phase asynchronous motorsfrom Siemens that feature slipring rotors delivering an output of9 MW each. The two motors in oper-ating mode S1 have an efficiency of97.2%. They are started in parallelby a liquid starter, which was alsodelivered by Siemens. However, thehighlight of the drive technology,apart from the gigantic size of thetwo mills, is in fact the gear-unittechnology. The semi-autogenousmill and the ball mill are eachdriven by two of these gear units.On a conventional drive variant,only one engagement per pinionwith the girth gear is possible perside, which creates a power limit ofabout 8 MW per drive. With its spe-

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cial DMG2 gear units, Siemens wasable to increase this to as much as12 MW per drive. “So the DMG2 wasthe right choice here,” says StefanoPellissetti, authorized managerand purchasing director at Cemtec.

<DFCI.= ?D^;=!DEOne reason for the high powertransmission is the self-aligningdrive pinions, which guarantee anoptimum contact pattern. The gearunit has an internal load-sharingsystem that ensures the powerbeing transmitted is always opti-mally and evenly distributed be-tween the two drive pinions, whichmesh with the girth gear, thanksto the free axial movement of theintermediate shaft. The gears arecase hardened and have groundflanks – the toothing quality ac-cording to DIN 3990 is at least 6 orhigher. The output pinions can tiltto ensure that they are always opti-mally adjusted to the profile of thegirth gear. Two fundamental ad-vantages result from this dual-pinion construction: at 570 mm,the mesh width of the tooth flanksis considerably smaller than on aconventional single-pinion solu-tion, and it does not require ex-pensive helical gear teeth and alarge-dimensioned thrust bearing.Consequently, the DMG2 is about30% smaller than conventionalgear-unit solutions.

4DDF =D FD9*FEM (finite element method) analy-ses were used to optimize the gear-

unit housing – making bearingreplacement on the input shaft, forexample, significantly easier. Inaddition, wear-free labyrinth sealsare used on the drive shaft. On theoutput side, a flexible bridge cre-ates an oiltight connection betweenthe housings and the girth-gearhood. An innovative oil lubricationsystem ensures optimum lubrica-tion of the pinion/girth-gear con-nection, resulting in higher effi-ciency and ultimately a longer over-all system service life. While a size25.4 gear unit for the semi-auto-genous mill weighs about 36 tons,a size 30 ball-mill gear unit weighsas much as 70 tons. “Here too, thisvery compact design has importantadvantages, because transportingsuch gigantic mill systems, alongwith their drive systems, is in itselfan incredible challenge,” explainsPellissetti. “As far as I know, thereis no other solution of this magni-tude operating in the mining envi-ronment.”

But Cemtec is already thinkingmuch further ahead. With theSiemens drive solutions, it could bepossible to generate outputs of upto 24 MW or more in this type ofapplication, so the productivity offuture systems could be 30% higherthan the current maximum output.Such a massive increase in outputwould be worth a mint to miningoperators.

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o extend the life of machinesand plants and avoid the riskof unscheduled downtime,

old drive systems must be replaced.But rather than representing a cap-ital loss on the balance sheet, retro-fitting an Integrated Drive Systemcan actually pay for itself withinmonths and boost profits for yearsto come. The replacement of exist-ing drives creates the perfect oppor-tunity to implement new energy-saving technologies that can im-prove efficiency and reduce costs.Siemens has been helping compa-nies gain these benefits with itsretrofit service for decades. Fromits enormous inventory of compo-nents and design plans, Siemenscan upgrade machinery to the lateststandards and thus boost perfor-mance. “Retrofits for IntegratedDrive Systems are Siemens’strength,” says Annett Stollberg,Siemens’ retrofit product lifecyclemanager. “Our approach takesthe entire drivetrain into account,not just individual components, inthe realization of energy savingspotential.”

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Upgrading the entire drivetrainwith a fully integrated solution isa long-term investment in energyefficiency and longevity. This caninclude changing from fixed-speedto variable-speed operation withfrequency converters, replacing DCmotors with AC motors, or migrat-ing to a gearless design. Whenthese upgrades are combined withdiagnostic capabilities, processescan be optimized to reduce energyconsumption without lowering per-formance. “What’s most importantis to understand the applicationand the customer’s requirementsfor the production process. In manycases we can offer a variety of solu-tions so customers can weigh upthe differences and advantages,”says Stollberg. “Once a customerhas chosen a solution, Siemensthen handles the entire engineer-ing process, from planning tocommissioning.”

@ (IE D( A*=ADO=?Hanson Purfleet now saves £175,000a year after reducing its energyconsumption by 36% following thesuccessful retrofit of an IntegratedDrive System in one of its fans.Previously the fan was poweredby a fixed-speed drive, runningcontinuously at 350,000 m3/hr but

UE,!9!,;I^ A*=ADO= ?D^;=!DE?Siemens offers a comprehensiveretrofit program for both its prod-ucts and those of other brands;the choices are tailored to theneeds of the individual customer.The first option is 1:1 duplicationof the motor: if the long-standingconfiguration is already deliver-ing proven performance and lowenergy consumption, an identi-cal motor can be selected fromSiemens’ extensive inventory. Thiseliminates the need for expensiverequalification of new machines.The second is replacement: an eco-nomical and efficient option, withthe lowest up-front investmentcost, is to replace the drive witha standard product. Additionalcustomization can then be per-formed in the factory or on-site.The third option is an upgrade:for the highest efficiency gains,upgrading old motors and drivesto the latest cutting-edge technol-ogy from Siemens’ product rangecan pay for itself within monthsthrough lower energy consumptionand optimized processes.

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damped to 241,000 m3/hr. Thismeant more than 100,000 m3/hrwas being wasted, thus addingconsiderable unnecessary coststo the company’s energy bill.

After Siemens retrofitted thefixed-speed motor, the drop inpower usage was dramatic. Themotor is now constantly monitoredwith sensors, and the airflow isregulated by a frequency converter.This system optimizes performancewhile ensuring that energy con-sumption never exceeds the opera-tional requirements. “The Siemenssolution means we are now run-ning with the damper open 100%of the time, yet actual energy con-sumption has dropped by around360–400 kW,” says Hanson Purfleetelectrical engineer Dave Jackson.

Along with energy savings of36%, the company has achieved a1,487-ton reduction in CO2 emis-sions. The large ongoing savingson energy bills mean that the en-tire Integrated Drive System willpay for itself within two years,highlighting how a Siemens retrofitturns capital expenses into long-term profits.

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ietnam is undergoing rapid industrializationand modernization. One of the results of thistransformation has been a substantial increase

in the country’s demand for cement. With a capacityof 12,500 tons of clinker per day, the new productionline at the Cong Thanh cement plant was built to helpmeet that demand. The increased capacity has madethe plant one of the largest cement-production facili-ties in Asia.

Siemens was contracted by the Cong Thanh CementJoint Stock Company, a subsidiary of the Cong ThanhGroup, to provide all the electrical and automationinfrastructure for the plant’s new production line,including cabling for the medium- and low-voltage

distribution systems, switchgear units, uninterrupt-ible power supply and battery systems, power factorcompensation system, transformers, low-voltage dis-tribution panels with intelligent motor control centers,and variable-speed drives. The scope of supply alsoincluded the majority of the process instrumentationfor the plant, along with the complete distributedcontrol system (DCS), which controls the variousstages of the cement production process.

3!E%^*M?D;A.* I,9IE=I%*?As is the case with any production facility, high up-time and reliability are critical to the operation of theCong Thanh cement plant. The implementation of an

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Integrated Drive System (IDS) from Siemens has beenfundamental in achieving these goals, as it providesa single point of contact for the entire drivetrain –which consists of motors for the mill, limestone crusher,and kiln, along with gear units, frequency converters,and control systems. In addition to allowing for rapidresolution of problems in the field, which effectivelyminimizes downtime, having a single provider elimi-nates the finger-pointing that is often prevalent inmultivendor engagements.

“By having a single provider, we’ve been able to re-duce interface losses, resonances, and wear by meansof design, engineering, and optimally matched com-ponents,” says Le Than, project manager at Cong ThanhGroup. “This translates into reduced operational andmaintenance costs, outstanding availability, andhigher energy efficiency. It also helps facilitate pur-chasing and lowers warranty costs, which is some-thing many cement manufacturers don’t always takeinto consideration.”

8C=!F!VI=!DE =#AD;%# !E=*%AI=!DEAt the heart of the plant’s automation system is Cemat,an integrated process control system from Siemens.Cemat has been installed at more than 800 facilitiesworldwide and is based on Simatic PCS 7. “Cematoffers many unique features that make operation ofthe cement plant simpler and more efficient, such asnumerous blocks and modes for advanced controlfunctionality,” explains Amos Todt, senior project

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manager at Siemens. “It also provides the capabilityto monitor all process components of the plant in realtime, which allows operators to quickly diagnose prob-lems and evaluate the status of various areas of theirfacility.”

In addition to providing the framework for inter-connecting drives, belt conveyors, dampers, andmeasuring equipment, the scalability advantagesoffered by Cemat and Simatic PCS 7 were a major rea-son for the solution’s implementation at the plant.

“We needed a highly innovative DCS that could helpus stay competitive over the long term,” adds Than.

“Cemat not only offers great compatibility with legacysystems, but it also gives us the ability to expand theplant if needed and integrate current infrastructurewith future innovations.”

QIZ!F;F CAD,;.=!9!=XSourcing from a single vendor allowed the Cong Thanhcement plant to leverage automation systems beyondthe cost of their implementation, according to Le TienDung, deputy general director of the Cong ThanhGroup. “Partnering with Siemens to implement theIDS met the needs of our facility,” he says. “We’vebenefited greatly from high energy efficiency, reliabil-ity, and reduced operational and maintenance costs –in simple terms, maximum productivity.”

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he cement industry is booming in SoutheastAsia. Indonesia, for example, has made signif-icant investments in new infrastructure in

recent years in an effort to modernize and promoteeconomic growth. One of the results of this effort hasbeen an increase in the country’s demand for cement.Indonesian cement producers are thus coming underincreased pressure to boost output and improve oper-ational efficiency in order to meet this demand andavoid supply shortfalls.

@E !FCDA=IE= !E,;?=AX C^IX*AIndocement Tunggal Prakarsa is Indonesia’s second-largest cement producer, yielding over 20 million tonsof cement per year. The company was founded in 1975and in 2001 was acquired by the German multinatio-nal giant Heidelberger Cement. Indocement operatesa total of 12 plants in Indonesia, located at three inte-grated cement factory sites. The company’s largestinstallation is its integrated megaplant at Citeureup,which features nine dry kilns and has a total produc-tion capacity of 13.6 million tons of cement per year.

Q!%AI=!DE (DA ?;..*??From its inception, Indocement has been committed tocontinuous improvement through integration and pro-cess optimization – hence the company’s decision in2013 to commission its long-standing partner Siemensto migrate the outdated control systems at three pro-duction facilities (Citeureup, Cirebon, and Tarjun) tothe Cemat integrated process control system, which isbased on Simatic PCS 7.

With a presence in Indonesia that can be traced backmore than 160 years, to 1855, Siemens offers a uniquecombination of expertise and local resources that madethe company a logical choice of partner for Indocement.

Furthermore, Cemat has been installed at more than800 facilities worldwide and represents a provensolution for helping cement producers reduce coststhrough advanced resource management and pro-ductivity monitoring.

@ ?!%E!O.IE= !FCAD9*F*E=The primary goal of the upgrade project was to im-prove reliability and efficiency at the production facil-ities so that Indocement could reach its productiongoal of 30 million tons of clinker per year by 2018. Inaddition to maximizing uptime and decreasing theoverall cost of production, the company wished toreplace the existing distributed control systems witha more advanced and integrated platform that couldprovide added visibility into the overall operation ofthe plants.

The project scope involved the migration of sevenproduction lines – four at Citeureup, two at Cirebon, andone at Tarjun. A new coal mill (a future project) will alsobe integrated into the new control system. The migra-tion of the production lines required the replacementof programmable logic controllers (PLCs) as well as theaddition of remote I/O substations and HMI upgrades.Prewired I/O rails with connectors were selected due toa need for short exchange time. Work at the facilitieswas performed by a combination of Indocement person-nel and Siemens engineers based throughout Indonesia.Having the advantage of worldwide presence, Siemensalso involved experts from India to speed up the com-missioning. Safe migration with minimum downtimewas Indocement 's main priority, and together withSiemens, this target was achieved.

Cemat provided an advanced framework for intercon-necting drives, belt conveyors, dampers, and measuringequipment and allowed Indocement to access relevantcement production data in a virtual real-time environ-ment. Simatic PCS 7 also offered superior compatibilitywith legacy systems and provided the flexibility to ex-pand plant capacity in the future if needed. Standard-ized libraries for automation functions also helped en-sure better maintenance and service – leading to lowercosts and increased efficiency at each of the facilities.

S*9*AI%!E% *ZC*A=!?*The expertise and global presence offered by Siemens,coupled with the operational experience of Indocement,allowed for a smooth upgrade at all the facilities. Thesuccess of the migration project has led to furthercollaboration between the two companies: the new P14kiln line will also be controlled by the Cemat system.This partnership is just one example of how a perfectfit between portfolio and expertise can create cost-efficient solutions that help improve reliability, reducecomplexity, and achieve long-term operational successfor cement plants.

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ith a production capacityof 61 million tons per yearand subsidiaries on four

continents, Italcementi Group is oneof the world’s largest cement pro-ducers. The company has repeatedlywon awards for its commitment toinnovation and sustainability, andcontinually sets new standards – forexample, with the modernization ofits plant in Rezzato, Italy, originallyput into operation in 1964.

@ ?=*C !E=D =#* (;=;A*The Rezzato project, given thegreen light in 2010, is proof of Ital-cementi’s future orientation. Oneof the company’s main objectiveswas to transition from a semidryclinker manufacturing process toa modern, more energy-efficient,and sustainable dry process. Forthe automation and process controlof the new line, Italcementi choseSimatic PCS 7 – as it had for vari-ous successful installations in thepast. The complete engineering,supply, and commissioning of thismain control system (MCS) wasawarded to Fast S.p.A., an experi-enced automation services pro-vider and systems integrator forSiemens.

P*\ CD??!G!^!=!*? \!=# 7ADOE*=Because the assets of a cement plantare often dispersed over a widearea, the design of the communi-cation network architecture is acritical issue in MCS engineering.Normally, a centralized layout isthe solution of choice – with allsmart devices located near the cen-tral control room, all peripheralsin the distributed electrical rooms,and all the devices connected viaa Profibus DP–based star or ringnetwork.

Rezzato chose a different ap-proach and became the first projectworldwide to use a unique Profinetring with Simatic PCS 7, which con-nects all the controllers to all theProfinet users. This solution, de-vised by C.T.G. (Italcementi GroupTechnical Center), was designedby Siemens and Fast S.p.A. and sig-nificantly simplifies the networkarchitecture. Any peripheral devicein any electrical room can be con-nected to any MCS controller, any-where in the plant – simply bymeans of optical fibers. In addition,it is possible to easily link third-party local programmable logiccontrollers (PLCs) into the networkand to access them for mainte-

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QDA* =#IE DE* A*I?DE =D .*^*GAI=*During the installation andcommissioning of the system,experts from CSMT (Centro ServiziMultisettoriale e Tecnologico – theProfibus and Profinet CompetenceCenter headquartered at the Uni-versity of Brescia) conducted exten-sive surveys and performance au-dits and also assisted in the detailengineering phase. With their di-agnostic tools, they could examineall network nodes, resolve connec-tion and configuration issues, andrelease network performance cer-tification reports.

Thanks to the close collabora-tion of all the participants, themodernization project was a bigsuccess. The Rezzato facility, whichbegan operating in 1964 during the100th anniversary of the foundingof Italcementi, started up its newline in November 2014 in time forthe 150th anniversary.

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