Operating services

• Total plant evaluation, technical audit
• Kiln evaluation and optimisation
• Raw mill evaluation and optimisation
• Cement mill evaluation and optimisation
• Kiln lining inspection
• Quality control programs
• Commissioning services
• General troubleshooting
• Energy audits  

Total plant evaluation, technical audit
A total plant evaluation consists of an inspection by experienced consultants who will visit the plant to evaluate the performance of all the departments in the plant, from the quarry to the packing plant. This evaluation will include:

• Process and production methods
• Quality and pollution control procedures
• Visual inspection of equipment
   

The consultants must have access to all relevant data concerning the machinery and to the performance records for the various departments.

The results of the investigation are presented in a comprehensive report which gives a general evaluation of the plant and the performance of each production area. The report will give recommendations regarding improvements that should be implemented, both for the plant as a whole and for specific areas. The report will also highlight any specific installations, methods or machines that have proved to cause repeated problems, or to be a bottleneck for production. This will then form the basis for a thorough investigation by a specialist in that particular field.

Kiln evaluation and optimisation
A thorough kiln evaluation and optimisation study covers the clinker burning process from raw meal homogenising to transport from the clinker cooler. A Customer Services specialist will visit the plant and, in cooperation with plant personnel, evaluate the kiln system through measurements of process parameters, analysis of available operational data and a visual inspection of the installation.

The specialist will also make suggestions for changes to operational procedures or process parameters in order to optimise the existing kiln operation. The Customer Services specialist can be contracted to assist in implementing these changes at the plant.

After the visit, in cooperation with the FLSmidth Design Department, the specialist's findings are compiled in a written report that contains an overall assessment of kiln performance, recommendations for optimisation of the installations and suggested solutions to specific problems, such as decreased production, increased energy consumption, reduced product quality, etc.

Regular kiln evaluation and optimisation studies are an indispensable tool for plant management and production staff, and provide a key to optimal kiln operation in terms of heat and energy consumption, as well as production rate and quality.


Raw mill evaluation and optimisation
A raw mill evaluation and optimisation program covers examination of the raw material grinding process from the mill feed to raw meal homogenisation.

A Customer Services consultant will evaluate the grinding process and installation by analysing mill feed transport, addition of corrective materials, drying, grinding, separation, energy consumption, auxiliary heating systems, dust transport to silo, quality control methods and dust emission control, as applicable in each individual case. The consultant will compile these findings in a report that gives an evaluation of the raw material grinding process at the plant and pinpoints issues of special concern highlighted during the visit.

Cement mill evaluation and optimisation
Much like the raw mill evaluation programme, cement mill evaluation and optimisation concentrates on the areas which are relevant to optimising the cement grinding process, namely clinker blending, addition of gypsum and additives, grinding aids, clinker grinding, separation, cooling, energy consumption, cement quality, transport arrangements to the silo and dust emission control. The results of a Customer Services specialist’s evaluation are compiled in a report with suggestions for future action.

For additional information, please see Brochures.

Kiln lining inspection
Customer Services consultants can be contracted to evaluate the performance of the kiln lining and, if possible, carry out visual inspection of the refractory lining or assist plant personnel in troubleshooting of lining problems. The consultant will act as an independent advisor, based on our extensive experience with the various types of lining materials. This experience includes the effects on the lining of kiln burner performance and the physical and chemical properties of the clinker. The Customer Services consultant's conclusions are compiled in a written report with relevant recommendations for improved refractory lining efficiency.

Quality control programs
A Customer Services consultant with a chemical background will assess the procedures for sampling and the methods of physical and chemical analysis of all raw materials, as well as intermediate and final products. Furthermore, the consultant will analyse all available production records. Recommendations for improving quality control procedures are highlighted in the final report.

Commissioning services
Individuals or teams of experienced Customer Services commissioning engineers can be contracted to carry out various commissioning activities, ranging from pre-operational checks to performance tests of machinery, plant sections or entire production plants. Our commissioning engineers naturally have extensive experience with FLSmidth equipment, but also with most other types of equipment for cement making, lime reburning, etc. Recommendations will be given on-site, either to plant personnel or to the existing commissioning team.

General troubleshooting
Customer Services consultants assist in troubleshooting of production problems at cement plants, or industrial facilities with similar machinery. Contracting a Customer Services consultant for urgent troubleshooting can usually be done at short notice.




Energy audits
Customer Services consultants specialising in plant management and process optimisation will carry out a thorough survey of the energy consumption at a cement plant and compare it with the industrial standard described in a comprehensive database of energy consumption of various types of machinery or plant sections. The results of the survey are submitted in a report, together with recommendations.