Automated energy monitoring & management system for cement production plants and other energy intensive use industries

Sector profile

The manufacturing process for Cement requires many energy-intensive industrial processes. Process heating of limestone, clay and marl occurs in specialized kilns (fossil fuelled), and includes calcining, drying, and sintering. Motors are used for a wide variety of grinding, mixing, and material handling systems to convey cement. Compressed air is used extensively to serve dust collectors, cylinders, air knives, and pneumatic clutches. Fan systems are needed in the kilns for the clinker cooling process and to aspirate and remove airborne dust in the baghouses where rocks are pulverized. Establishing an energy management system (EnMS) can help cement plant management better understand how energy is consumed in the facility and how energy efficiency solutions can be devised and implemented effectively.

Electrex Automated Energy Management System

The Electrex solutions allow:

  • The capture of energy consumption information, automatically making it possible for energy managers to avoid time consuming manual tasks such as writing down values from energy counters.
  • More insight about energy consumption and its patterns (normal / abnormal consumption).
  • Automatic feedback (or alerts) to personnel who can take action to stop energy waste.

The Electrex Automated Energy Management System architecture design is based on three main elements.
Measurement devices and data collection:

  • Our microprocessor based energy analyzers, I/O devices and sensors offer advanced features that go beyond those offered by pulse output devices or analog meters. Our smart devices assure a direct and very fast access to measurements and information. Because energy consumption is directly connected to temperature, luminosity, production cycles, tenants, etc. we measure environmental and process parameters and integrate third party devices.

Data-logging and communication:

  • Our devices are equipped with built in memory, clock and calendars in order to locally store high frequency critical measurements using a redundant and multi-nodes approach. In this way no data can be lost due to communication or system failure. The built in or external communication modules use the most open and transparent protocol Ethernet TCP/IP. It offers reliability, integration with other systems and direct access from each level / stakeholder.

Data analytics, reporting and publishing:

  • Our solution uses three main platforms; built-in web server in each device; PC based software and cloud interface. Each of them allow the management of automatic real-time and historical data, configure alarms and notifications, and deliver custom reports. We believe that the user is the owner of the collected data. We offer complete flexibility and the required tools to get the most out of our platforms.

Case study:

  • The diagram below represents a part of a monitoring network (sub-metering can be extended) in a cement production plant. The same architecture can be anyway applied to other energy intensive industries as the consumption drivers are similar.

Electrex – Energy monitoring network in a production plant

The facility of this case study is powered by a main MV load and equipped with 3 MV/LV transformers (one of them replaced recently). The 3 MV transformers serve the 3 production lines, while the offices are powered by a LV system. The monitoring system consists of branch 1, 2 and 3 for monitoring the transformers and part of the production lines while branch 4 and 5 controls the office areas.

The 5 branches are connected to the internal LAN Ethernet network via:

  1. Exa net D6
  2. Kilo net Wi-Fi D6 via Wi-Fi
  3. Yocto net D6 Web
  4. Yocto net Coordinator E-Wi EDA
  5. Femto ECT net Wi-Fi EDA D6 via Wi-Fi

The various instruments and sensors connected in the 5 branches monitor and control the principal loads. Because the system is modular and scalable, more nodes will be added in a next phase. In addition to adding new devices in a seamless way, our equipment is a Hardware-Ready type. Through PUK code entry via the Web interface of the device, new functions can be added and existing functions upgraded.

  • In branch 1 the Exa net D6 (gateway and data-logger) and the Exa D6 connected to the RS485 port of Exa net monitor two compressors while the Yocto I-O counts the gas, water and compressed air consumption. The RS485 Module is connected to analog sensors previously installed.
  • In branch 2 for the monitoring of Power Quality and energy consumption the Kilo net D6 (gateway and data-logger) has been placed under Transformer 1 while the X3M 96 H under Transformer 2. The ExpBus module connected to the Kilo net is used for alarms and pulse counting while the Exa TR connected to the RS485 port is one of the various transducers used for monitoring the production machines. The Femto D4 70A ECT is used for the monitoring of an area with LED lighting systems. The Energy Automation option has been activated in Kilo net device in order to automate the switching of various loads commanding the digital outputs built-in the Exa TR.
  • As the position of the Transformer 3 was distant from the Ethernet nodes, for branch 3 a Yocto net Web D6 (gateway data-logger) has been used. Connected to it via Rs485 has been installed the Exa F Rs485 with flexible split CT (easier to be mounted) and an Exa D6 MID used to monitor the energy used in a galvanic process for tax deduction purposes
  • In branch 4 a Yocto net Coordinator E-Wi has been installed serving as a gateway and data-logger for a Deca Sensor E-Wi that monitors environmental parameters in the laboratory.
  • Branch 5 monitors both sides , DC load and AC load (Femto D4 and Atto D4 DC), of a 10 kWp PV system placed on the office roof. In the same monitoring network a Yocto Net Web D6 Master has been installed that also hosts customized web pages for the system supervision. This is used by plant managers and access is via PC, tablet and smart-phone. On the same device the Alert and Notification option has also been activated which sends e-mails to the maintenance team in case of anomalies.

The Energy Manager is able to use a laptop, for local or remote connections via Ethernet / Internet, in order to control the effectiveness of the energy efficiency solutions. Analysis of the data downloaded periodically from the software Energy Brain, controls specific loads via the built-in web interface on each device and reacts to alarms and notifications displayed on every device equipped with a browser (smart phone, tablet, PC, etc.).

About Electrex

Since 1993 Electrex designs, develops, manufactures and markets, instruments and software for energy measurement, management and control.

The Electrex solutions are used in the energy efficiency and Energy Automation applications, for the industrial, commercial, public, civil, and renewable energy sectors allowing a rapid return on investment.

Electrex, one of the first companies to operate in these sectors and has acquired over the years a considerable experience and competence that few other companies can claim to have. With over 40% of the staff dedicated to R & D, we demonstrate our strong commitment to innovation and continuous improvement in order to anticipate the needs of our customers.

We follow our products from design to after sale service and support, being a flexible and dynamic company. That is why Electrex continues to be chosen more and more from both local and international partners.

The Electrex products are entirely designed, engineered and manufactured in Italy.

Learn more about the Electrex range of energy management systems and sub meters or contact Power Quality Expert for more information.

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