Since some low-voltage motors in the cooling system had reached the end of their service life after years of use, Hanson Cement brought Siemens on board as its long-term partner who had already successfully completed modernization projects at the company’s Purfleet and Ribblesdale facilities. The goal: a comprehensive, energy-efficient solution for the cement plant in Ketton. Hanson Cement and Siemens wanted to eliminate energy guzzlers in the production process. They focused their attention on the low-voltage motors in the cooling phase following the rotary kiln.
Taking another approach, they not only wanted to produce sustainably
with greater energy efficiency, but also ensure operating reliability.
Every single day of unplanned downtime at Hanson Cement’s Ketton plant
costs a small fortune. The digital transformation of the plant’s
critical drive systems was to play a key role here.
At Hanson Cement in England, the road to success is paved by investments
in reliable, energy-efficient drives and a long-term, future-oriented
partnership with Siemens.
The cooling system was upgraded with new SINAMICS G150 variable speed drives and new state-of-the-art low-voltage motors. The connected drive systems are directly and efficiently monitored via PROFIBUS.
In a second step SIDRIVE IQ Services like Expert Assistance and Expert Diagnostics were implemented,valuable condition and operating data of the connected SIMOTICS HV M high-voltage motors and the SINAMICS PERFECT HARMONY GH180 frequency converters help make the plant’s operation more reliable.
For Hanson Cement, investing in the digitalization of its plant’s drive system technology not only means cost savings, but above all minimizing the risk of downtimes. Thanks to the flexible drives, cooling the clinker can now be controlled far more accurately, which also improves the product quality. In the end, the project demonstrates that cost-effectiveness and sustainability need not be competing goals. At any rate, Hanson Cement is planning further investments to ensure the company’s success for the next 25 years.
The most important benefits at a glance:
Higher plant availability through 24/7 expert support
Energy cost savings of 86,000 £/year
Increased sustainability through annual savings of 711 tons of CO2
Hanson Cement's Ketton plant, England - Partners for a successful future
Hanson Cement's Ketton plant, England - Partners for a successful future
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