Being able to address a reduction in energy usage and increase the plant availability have become key targets for industrial companies. That's why Hanson Cement decided to upgrade their motors and converters by the Integrated Drive Systems (IDS) concept.
The Siemens solution included the implementation of each of the drive chains, which formed the control system IDS as totally engineered solution.
The total solution included six G150 SINAMICS converters - ranging from 45 kW to 160 kW - and pressure differential instruments for PI loop control, interfacing into the current DCS system via Profibus. These particular converters used enhanced energy-saving functions. The insulated bearings also fit to the existing motors at the plant.
Full power and control cable upgrades were also included completelly with a full site installation and commissioning of the complete clinker cooler process.
The clinker cooler upgrade project at Ketton carried out by Siemens has resulted in an annual CO2 reduction of 771 tonnes and over 86,000 pounds saved in energy use - much of it through the use of variable speed drive technology and Siemens' integrated Drive Systems Technology (IDS).
The return on investment for Hanson has also been achieved in less than 14 months with an additional environmental benefit: lower noise levels and vibration at the clinker cooler plant, improving conditions for the workforce as well as for the surrounding environment.
Trevor Jibb, Hanson's electrical engineer (designate) at Ketton, was delighted with the benefits of the clinker cooler upgrade: "The significant energy savings we've already made, coupled with the reduction in carbon footprint mean that Ketton continues to be a great example of best practice within our Group."
Hanson Cement, which is part of the global Heidelberg Cement Group, was the first UK cement producer to carry out annual environmental audits of its sites. The Ketton site, near Stamford, is a flagship in working with local conservation groups to protect the biodiversity of the flora and fauna in and around its quarry. Ketton has been a cement works since 1928 and is today one of the most efficient ones in Europe.
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