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Simatic PCS 7 process control system. The energy management system collects detailed information about energy consumption and costs, and prepares it for energy efficiency analyses. First and foremost, the transparency of the current flows in the medium and low voltage energy distributions needs to be improved – right down to the individual loads. This, coupled with the consumption data of other media such as fuels and other process energies, facilitate energy-efficient production processes. If major differences in consumption occur, energy peaks can be identified and eliminated by comparing different parts of the plant or manning of the shifts. The old adage, "You can't control what you can't measure," can truly be applied to energy management. In the Rohrdorf cement works, energy consumption is measured by the Simatic S7 automation system, and stored in an SQL database. This can then be evaluated, and displayed in Excel in either graphic or tabular form. This information can also be accessed by a Web client. The system displays the status of the low-voltage switches, and the current actual values of the electric current, voltage, etc. The link is provided by Profibus devices. However, the current stage of expansion does not permit operation of the low-voltage controls. The total consumption is accumulated, and the adjustable power setpoint is monitored. These setpoints are input each week in a 7x24 matrix. This enables the Rohrdorf cement works to keep within the supply limits agreed with the power supplier. Parts of the plant have to be switched on and off to comply with the agreed power intake from the electrical power system. The system supplies relevant messages to help the operator in the control center to do this. The operator then decides, for example, whether to shut down a cement mill completely. Such a system for measuring, managing and analyzing energy consumption data further increases the benefits of energy management programs. As these examples show, an investment in technologies for efficient energy use pays off within a short period of time. This benefit becomes particularly clear when the efficiency of the use of energy and resources is increased. If they use less energy and resources, they can work more profitably. Lubrication for high endurance In cement production, your components constantly endure heavy loads, high temperatures and invasive dust. That's why the industry relies on Klüber specialty lubricants to protect and enhance system performance. With specialty oils and greases for your mills, rotary kilns, dryers and more, you can benefit from Klüber Lubrication throughout your entire production system. Reliable operation, reduced maintenance expenses and longer system life — that's what we call effective lubrication. Contact us to learn how Klüber Lubrication can improve your bottom line. Klüber Lubrication North America L.P. info@us.kluber.com www.klubersolutions.com/cement2 your global specialist Information for this article courtesy of Siemens, www.siemens.com/cemat. www.cementamericas.com • Fall 2013 • CEMENT AMERICAS 11