Cement control solution exceeds expectations

As a result of deploying Pavilion's control solution on a kiln and finish mill, Dyckerhoff's Lengerich site has increased production by 4 and 9% on the two installations, respectively.

Pavilion Technologies' first project at Dyckerhoff's Lengerich site in Germany has delivered benefits in excess of expectations.

As part of the enterprise agreement Dyckerhoff forged last year, the company will now deploy Pavilion's control solutions at six additional sites throughout the company.

As a result of deploying Pavilion's control solution on a kiln and finish mill, Dyckerhoff's Lengerich site has increased production by 4 and 9% on the two installations, respectively.

In addition, the kiln operation has been significantly stabilised for the use of multiple types of alternative fuels.

These results exceed those identified as part of the initial Pavilion ValueFirst benefits analysis.

"Pavilion's control solutions have delivered significant benefits very quickly, helping us to simultaneously increase our use of alternative fuels and maximise production", said Dyckerhoff's Director of Technical Department, Herbert Reckziegel.

"In addition, Pavilion's team of skilled engineers has been an excellent compliment to Dyckerhoff's culture of continuous improvement within the organisation".

Like many European cement manufacturers, Dyckerhoff uses alternative fuels in its cement kiln operations.

With the Lengerich project, Dyckerhoff addressed an important issue.

The company successfully increased the use of alternative fuels without compromising production rate, product quality, reliability or safety.

Dyckerhoff realised the following benefits: in the kiln control application a feed rate increase of 4.2%, alternative fuel usage stabilised beyond 50% heating input and application uptime of 98%; and in the mill control application increase in production of CEM I 32,5R by 9.3%, reduction in energy consumption of 5.8%, increase in production of CEM I 42,5R by 4.5%, reduction in energy consumption of 2.4% and application uptime of 97.8%.

Cement companies today are constantly challenged to meet market demand, reduce operating costs, increase use of alternative fuels, and maintain environmental compliance.

Pavilion's cement solutions provide process control and optimisation across all key areas of the manufacturing process, enabling companies like Dyckerhoff to stabilise production and enhance quality while minimising the effects of process upsets to maximise efficiency.

"Leaders like Dyckerhoff depend on us to help them continue to drive down costs", said Pavilion's CEO and President, Ralph Carter.

"Through our ValueFirst customer engagement methodology, we stand behind our commitment of customer value and are pleased to play a part in Dyckerhoff's business success".

Pavilion's Cement Solution has helped major and regional cement producers to quickly meet customer demand, while simultaneously reducing costs and maintaining environmental compliance.

Pavilion provides a process control and optimisation solution across all key areas of the manufacturing process.

Pavilion provides cement mill control, vertical raw mill control, kiln control, environmental compliance and reporting and production performance management.

These applications leverage the company's strong domain expertise and powerful Pavilion8 technology for modelling, control, monitoring, analysis, visualisation, and integration.

As a result, customers achieve faster time to value and greater long-term value than alternative solutions.

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