The entire process, including over 6,000 field signals, is monitored from our central control room. A recent capital project included the renovation of our central control room, our server room, and the software/hardware for the finish mills.
The finish mills utilize Siemen's PCS7 software w/Cemat and S7-400 PLCs. The rest of the plant continues to use a hybrid Honeywell TDC-3000 and Allen Bradley PLC-5 system which was installed in the mid-1980s. Specialized software includes Quadtek's optical pyrometer (for burner temperature readings), Raytek's CS200 (for kiln shell temperature monitoring), Nexus Solutions CEMView (for emissions monitoring and reporting), and ABB's Expert Optimizer (for process optimization and "fuzzy" control).
The temperature profile of the kiln shell is closely monitored using a device that scans the temperature as the kiln turns. A real-time detailed temperature profile is displayed (upper graphic) in the control room and can be compared to historical data (lower graphic).
Both the CCR and lab monitor real-time quality information from our various systems. Shown is the lab control center.