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efficiency, quality and master and strengthen existing plant operations and, in
emerging markets, to quickly gain a better market share
Production Resource
Optimisation
[May 12] Reprinted from worldcement.com
Table 1. KPI impact on revenue from COO perspective ll RF (reliability) = operation
KPIs Average Top 20% The The hour / (opening hours - planned
(as target) best worst shutdown hours - stoppage hours
RF (reliability factor) 93% 98% 99.5% 68% due to circumstances) x 100%.
PF (performance factor) 92.5% 98.5% 120% 75% ll PF (performance factor) = average
Impact on revenue (top 20% vs kiln output / rated capacity x 100%.
average) ll MTBF (mean time between
Annual clinker production of one line 1.51 1.69 failures) = total operation hours
(million tpa) in a year / number of stoppages
Total clinker production in the 75 84 for incidents.
company (million tpa) ll Clinker volume (yearly
Additional clinker if optimised 9.2 production) = rated capacity
(million tpa) x 365 x UF x PF or = rated
Company additional profit 276 capacity x (365 - planned
(million US$ pa) shutdown days - stoppage hours
due to circumstances) x RF x PF.
The number of equivalent clinker lines 6.1
Notes (assumptions)
Benchmark
Rated capacity of one clinker line 500
For well mastered cement plants, the
(tpd)
kiln RF can reach 99.5%; the annual
Planned overhaul shutdown (days) 15 UF can reach 96%; MTBF can reach
Margin from clinker production 30 30 days, with a longest record of
(US$/t) 145 days continous running; PF
Annual clinker production for one line 5000 x (365 reaches 98 – 120%.
(15 days for planned overhaul, 0 days - 15) x RF For average plants, the kiln RF is
for external circumstances) x PF about 90 – 93% (many companies do
Total clinker lines in the company 50 not even measure this); the annual
UF is around 85%; MTBF stands at
5 days and PF at 92%.
For poorly managed plants,
the kiln RF averages 68%; the
annual UF is <80%; with MTBF of
2 – 3 days and PF of 75%.
Example
Adelaide Brighton Cement Ltd, Australia, implemented
downtime management, the result of which is illustrated
in Figure 4.
The Adelaide Brighton example demonstrates how
a modern IT solution provides a tool for continuous
improvement. Not only did the implementation of
Ampla reduce downtime stoppages and slow running in
the year of implementation, it continued to facilitate y/y
continuous improvement.
Energy optimisation
Energy optimisation covers energy consumption
and energy costs. The typical energy cost structure is
illustrated in Figure 5.
Case study
A plant in Beijing, China, reduced its power
consumption from 121 kW/t to 100 kW/t by
following a 3 year intensive improvement
programme. However, the positive results
that were achieved were not improved upon
Figure 4. Adelaide Brighton Cement Ltd, Australia, reduced kiln stoppage with further. This was due to a variety of factors,
downtime management.2 the most important being that the plant did
Figure 7. Plant power consumption on air compressors. l The temperature of cooler exhaust air (T of cooler
exhaust).
Sustainable development
Cement, especially clinker manufacturing, is a
carbon-intensive transformation process:
ll 1 t of clinker production generates 0.8 – 1.1 t
CO2.6 This depends on: MJ/t, kWh/t and loss
from (CaCO3 + MgCO3).
ll 1 t of cement production generates 0.5 – 1.0 t
CO2. This depends on: C/K ratio and kWh/t for
finish grinding.