Cement Plant Recipe-Based Process Automation and SCADA

Scope of work

• PLC automation of dosing, mixing and dispatch systems
• Recipe definition and batch setting screens
• Integration of the weighing system into the automation
• Belt conveyor and dosing line control
• Manufacturing of the plant automation panel
• SCADA mimic screens and batch reporting
• Field installation and commissioning

Technical solution

Recipe-based production

Material ratios, dosing tolerances and mixing times are defined as a recipe for each mix type. The operator selects the recipe and the number of batches; dosing, mixing and discharge steps then run automatically in sequence. This keeps the same product consistent from batch to batch.

Weighing integration

Dosing accuracy depends directly on weighing data. Weighbridge signals were taken into the automation system, cut-off points were set from the actual measured weight of each material, and out-of-tolerance batches are reported to the operator as a warning.

Batch reporting

Recipe name, target and actual material quantities, date-time and operator are recorded for every batch. These records serve both production tracking and, where a customer requires it, batch-level documentation.

Dispatch and conveyor control

The belt conveyor and dosing line are programmed to run interlocked so that material flow is never broken. A stop anywhere on the line brings the upstream equipment to a controlled halt as well.

Outcome

Production is no longer dependent on operator habit; it is repeatable and driven by defined recipes. Because records are kept per batch, output volume and material consumption can be reviewed retrospectively.