Plant evaluation concerning how to evaluate the performance of your plant which includes measurements of process parameters, analysis of available operational data, quality and visual inspection of equipment. Plant evaluation and optimization studies are an indispensable tool and provide a key to optimal operation in terms of heat and energy consumption, as well as production rate and quality

A total plant evaluation consists of an inspection by experienced consultants who visit your plant to evaluate the performance of all its departments, from the quarry to the packing plant. This evaluation includes: 

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

The results of the investigation will give recommendations regarding improvements that should be implemented, both for the plant as a whole and for specific areas. It will also highlight any specific installations, methods or machines that have proved to cause repeated problems, or to be a bottleneck for production and modifications. In short, from total plant evaluation to assessment of specific processes, will help you to optimize your operation. It may changes to operational procedures or process parameters in order to optimize your operation and suggested solutions to specific problems, such as decreased production, increased energy consumption, reduced product quality, etc.

 

Preheater and Calciner Optimization

 

TigaDaun Engineering is your specialist in preheater optimization as well as calciner optimization. The core of the pyroprocess of each modern cement kiln is the preheater. Most substantial thermo-chemical reactions of the cement process occur in the riser ducts and in the calciner(s) and certainly in the sintering zone of the kiln. Modern suspension preheater kilns usually have 1 or 2, in a few cases also 3 strings with 4 or 5 stages. Preheater optimization is essential to increase the productivity and/or energy efficiency of a kiln.

To design an optimized solution for the preheater optimization, a detailed analysis of the existing operation parameters at the plant has to be conducted. This study normally includes the peripheral equipment such as ID fans, clinker cooler, mills and filters to compile a complete heat- and mass balance of the kiln system.

Based on these parameters, the optimized concept and layout for the modification of the preheater is then elaborated, utilizing as much existing equipment as possible and existing fans to keep the investment costs low.

 

Feasibility Studies

 Our expert has worked for detailed feasibility study of cement plant including market analysis, logistical issues, project viability and production process evaluation.

 

Environmental Studies and Impact Assessments

Our clinet are increasingly faced with the challenge of meeting the requirements of more stringent legislation and maturing community expectations. As result, environmental impact assessment are becoming a central element of development approvals on a global need. We identify opportunities to audit and improve your environment management system and minimize risk of environmental fines.

 
Development of an Alternative Fuels Strategy

The cement industries have set future targets for using alternative instead of fossil fuels. And the suppliers are following suit the necessary technology is increasingly becoming an integrated part of the production systems. The cement industry can play an important role in the quest for a low carbon society. Using waste streams as fuels in a cement kiln can:

• reduce the quantities of material going to landfill
• recover energy from combustible wastes
• conserve fossil fuels
• reduce cement production costs
• improve environmental performance
• reduce acid gas stack emissions.

Talk to us about technical services to support your alternative fuels strategy.

• Survey and analysis of waste streams
• Process analysis and kiln performance modelling
• Specifications for waste fuels
• Feasibility studies and cost-benefit analysis
• Environmental studies and impact assessments
• Quality control procedures
• Design of fuel reception, storage, blending and dosing systems
• Specifications for the process, equipment, control system philosophy
• Operational trials of waste fuels
  
  

Research and Development

As a knowledge-based company, our research and development provide analysis of a broad range of materials and processes. A major goal for our research and development effort is therefore to improve energy and emissions efficiency of our products and services.

We conduct feasibility studies ranging from specific area to a new cement plant . We also have the capability and expertise to design your plant, and optimize it for profitability. Each application is analyzed based on raw material characteristics and product quality requirements before the optimum technology is selected 

Technical Training

Cement manufacturing is highly dependent on the individual processes involved. If one link in the chain of the production process is of poor quality, the entire production will suffer.  Therefore a production personnel needs to having a comprehensive understanding of a whole processes involved in cement manufacture, and how each process influences the subsequent processes in the production. More training than ever before to build competence and sharpen your competitive edge

The objective of our training program is to enhance competencies needed for performing specific tasks or jobs of the employees in plant operation. A well-trained workforce ensures efficiency, and reduces the need for specialist trouble-shooting. Further on, this training program provides plant personnel with updated knowledge resulting in major improvements in productivity and performance, all measurable on operation 

To support performance of the operation, maintenance and repair activities are critical components in assuring the efficiency of the cement manufacturing plant. If not maintained properly, equipment run-time will be reduced, causing substantial economic losses. In particular, the maintenance personnel responsible for the maintenance of the equipments according to prescribed instructions to significantly improve the performance of the plant and increase plant efficiency.

We gain specialist knowledge and understanding providing standard courses as well as tailor-made training to plant operators and engineers. Under the main subject areas to be specified, each course is planned in detail with respect to training objectives, training methods, training material, lesson plan and course evaluation.

The subjects of interest of our regular courses in the areas of production, mechanical and electrical maintenance, and also related subjects which will ensure the optimal production and high level of equipment availability. Training can be arranged at a local plant site as in-house training and participants may come from the plant, thereby making attendance less costly.

Our instructors have experienced work in cement  plant in more than 10 years. They know how to optimize plant operation, and they know where and why typical problems occur and how to solve them. This range of experience makes us particularly skilled at designing and delivering training that is relevant to your specific needs and to sharing our experience and expertise.

 

Process Production Modules

• Mining Operation
• Kiln Process Operation and Optimization
• Raw Mill Operation and Optimization
• Coal Mill Operation and Optimization
• Cement Mill Operation and Optimization
• EP and Bag Filter Operation
• Quality Control Improvement
• Laboratory and Microscopy Analysis
• Alternative Fuel
• Low Grade Coal Utilization
• Technical Audit in Cement Plant
• Emission Reduction Strategy
• Combustion Engineering : Burner and Fuel Technology
• CFD Simulation for Cement and Mining Application

 

Mechanical Maintenance Modules

• The Maintenance Management
• Reliability Centered Maintenance
• Hydraulic and Pneumatic
• Pump, Blower and Compressor
• Kiln Maintenance
• VRM Maintenance
• Ball Mill Maintenance
• Gearbox Maintenance
• Mechanical Design & Analysis
• Plant Commissioning
• Coal Mill Maintenance
• Cooler Maintenance

 

Electrical and Instrumentation Maintenance Modules

• Process Control System
• Electrical and Instrumentation Maintenance Practice
• Plant Automation
• PLC and DCS
• Instrument Configuration & Calibration
• EP Maintenance

 

We also provide human capital development to encompass an examination of the areas to help describe and specify the recommendations that can improve your plant’s overall performance.

• Job Value
• Technical Competency Development
• Job Description Development
• Technical Gap Analysis
• Technical Assessment Center