2

You need to reduce your consumption to be

more competitive and respond to your

sustainable development objectives.

We recommend energy audits helping you

modernise your installations to reduce your

energy consumption by up to 5%

Our expertise in

energy effi ciency

The cement industry

consumes 1% of world

energy

Benefi ting from the dynamic economies of emerging regions, the cement industry has

shown steady growth and record production levels.

With such a promising future, signifi cant investments will be required to increase current

production capacities and to meet new environmental and energy constraints.

Countries

have cement industry

operation.

3

You want to follow market

developments

To respond to customer expectations, you have

numerous challenges:

- Build new production units while optimising

your investments.

- Improve quality and reduce operating costs

of existing installations.

- Achieve your sustainable development objectives

by reducing greenhouse gas emissions and energy

consumption and by applying specifi c measures

for the safety of man and the environment.

We can help you achieve

your objectives

Experts in systems architecture design, automation,

process control and energy effi ciency, we have

been developing performance and cost-optimised

solutions for the cement industry for many years.

These solutions meet the needs of Production as well

as Engineering and Maintenance, enabling them to

concentrate on their core activities and achieve their

specifi c objectives.

Billion tons

Global cement

production in 2006.

Synergy of tools

Our solutions are based on a suite of integrated tools

for optimising the design, monitoring, and

management of your processes for maximum

productivity. They use the highest-performance

components and software on the market to meet

criteria of reliability, durability and profi tability

of your investments.

Open communication network

Architectures based on Ethernet TCP/IP provide

the greatest openness and transparency at all

levels of the enterprise. Ethernet simplifi es your

overall communications infrastructure by expanding

the horizon of components and innovation, and

it provides consistency and simple integration of

factory systems with business level communications.

Cost control on new site development and existing site extension

is a key issue based on strategic choices for the future.

lD e s i g n n e w c e m e n t p l a n t s a t m i n i m u m c o s t

4

Chang SiYongElectrical and

Automation Engineer,

Lafarge, Shui-Dujiangyan

“The Schneider Electric

system has helped us

considerably reduce

programming and

installation time, to

control and secure these

phases and consequently

to minimise delays in

commissioning.

The integrated process

control oriented function

library is comprehensive

and in phase with

Lafarge methodology

and specifi cations.

The Schneider Electric

open process control

system itself generates

a signifi cant proportion

of the PLC and HMI

programming. On its

own it eliminates most

bugs and reduces

development time.”

Don’t waste time designing everything

Our automation architectures and their specifi c

functions are tested, validated, and documented.

These proven solutions help you save time

(and money) from design to commissioning.

And don’t do the same thing twice

With our structured design tools and dedicated

cement object libraries, you reuse best practices

in the context of new installations and factory

modernisation or extensions.

5

average return on

investment for clinker

process control and

energy management

systems.

6

J.J. G.Plant Manager, Brazil

“Existing cement plants

are running at or close

to full capacity to answer

to the insatiable demand

of the growing markets.

Vijeo Citect provides us

the best information to

expand our production

with little or no leeway.

And to this end, profi ts

are beeing ploughed back

into capital expenditure.

As profi ts increase; so

does public expectation

of the community’s

health and safety track

record. Vijeo Historian

is an easy-to-use and

secure tool for plant

and IT staff to meet the

compliance requirements.

Beeing diligent in these

detail the attractiveness

and competitiveness of

the company strongly

increase.”

A high quality fi nished product

Our process control and optimisation

systems are critical in assuring you of

the best possible cement quality:

- optimising the blend of raw materials,

- improving the measurement and control of

airfl ow, temperature levels, weight, pressure,

emissions, material balance and energy use,

- improving grinding, combustion,

and conveying operations,

- enhancing the management of fi eld

instrumentation.

Maintenance, a source of savings

Critical point analysis of your process associated with

monitoring tools enables anticipation of breakdowns.

On one hand you minimise unexpected

maintenance operations and reduce the

production shutdowns they cause. On the other,

you programme your maintenance operations

and speed up restart of your installations.

Accurate information for good decisions

Product quality, optimisation of installations

and cost reductions require actions beyond

automation and supervision levels.

Our Manufacturing Execution Systems (MES)

are business intelligence and know-how tools

essential in determining opportunities for:

- improved production performances,

- increased margins and competitiveness.

MES solutions enable management, corporate, IT,

factory and production to transform factory real time

data into “business” decisions at all enterprise levels.

The quality of concrete produced by

your customers depends directly on the

quality of the cement coming from your

factories. Malfunctions during production

can have serious consequences, leading

to production losses and signifi cant

fi nancial penalties. To control or even

anticipate developments at each

stage, to intervene in real time, and to

use high-performance management

tools are essential in optimising the

quality and productivity of your sites.

l I m p r o v e q u a l i t y a n d p r o d u c t i v i t y

fossil fuels replaced

by alternative energy

source (coffee bean

shells) for cement

production in Africa.

reduction in electrical consumption

by using advanced process optimisation

and control.

7

Process control and energy effi ciency

go hand in hand

Grinding is one of the most important steps in

making cement. Overgrinding not only reduces

the strength of the fi nal product, but it also

consumes more energy than necessary. With

proper process control and monitoring capabilities,

you can ensure a high quality end product with

the minimum amount of energy consumed.

electrical

consumption in

the cement industry

is by machines and

equipment.

Consume smarter to save more

Reducing energy consumption is a major fi nancial

issue. Energy management technologies give

you a global view of your electrical installation,

allow you to regulate consumption peaks, help

detect unusual patterns of consumption, and

signal equipment faults. They also help you to

measure, monitor and quickly intervene in order

to maximise energy reliability and availability.

8

Cement production accounts for around 1% of the world’s energy consumption.

As a cement producer, you are under increasing fi nancial and environmental pressures

to fi nd ways to minimize your energy use. Optimising your production processes and

improving energy effi ciency are two ways in which you can achieve real energy savings.

l O p t i m i s e e n e r g y p e r f o r m a n c e

percentage of production costs that can be

attributed to energy (electricity and fuel).

Electric motors, a critical target for

energy effi ciency

Variable speed drives are an excellent way to

optimise the energy effi ciency of electric motors,

like those used for fans, pumps and conveyors

throughout the plant. Your benefi ts are immediate:

- Signifi cant energy savings from reduced energy

consumption.

- Optimised process control thanks to the ability to

send real-time feedback to automation systems,

thereby improving kiln and mill operations.

- Longer motor life and reduced maintenance costs.

For permanently available energy

Electrical supply failures mean immediate production

shutdowns. These shutdowns lose time and money

that can never be recovered. And you can’t predict

when production will be able to restart. Secure

power systems based on uninterruptible power

supplies are essential to maintaining production

during power cuts.

9

J. M.Electrical and Automation engineer

CEMEX, Mexico

“Our electrical consumption information is now

available 24/7 on CEMEX’s global intranet to everyone

who needs it.

For our operations areas, the EMS from Schneider

Electric is a key information tool that provides

instantaneous access to accurate information and also

automatically generates energy reports that eliminate

the effort and errors associated with manual data

recording.

We also use EMS information to implement demand

and power factor control strategies. Historical data

from the Schneider Electric system is very important to

our Maintenance Department since detailed operating

parameters like voltage, current, demand and power

quality, are readily available to our maintenance

managers who can use this information to schedule

preventive maintenance or, using the power quality

and reliability information, target corrective actions to

reduce downtime.”

10

The cement industry is responsible for 5% of global CO2 emissions produced by man.

It is a sensitive industrial sector directly concerned by the problems of sustainable

development: climate change, air and water pollution, management of natural resources,

health and safety of production personnel.

l S u s t a i n a b l e d e v e l o p m e n t

Global approach: a source of progress

We are all concerned by sustainable development.

Each of us in our own way can make a positive

contribution. You, by taking into account the

constraints and objectives of your operation and its

effect on the environment. Us, by offering technical

solutions that respond to your needs for today and

beyond.

A major challenge: reduce gas

emissions

Gas emissions can be reduced by optimising the

complete production cycle, notably in the combustion

process and by reducing energy consumption. Use

of our integrated automation system platforms,

associated with 3rd party gas monitoring systems,

provides you with real time data on gas emissions.

You are able to take proactive steps to reduce gas

emissions and protect our environment.

Eric PilaudExecutive VP - Strategy,

Customers & Technology,

Schneider Electric

“Schneider Electric

deploys action plans to

consume better and less.

We undertake with our

customers to signifi cantly

improve their energy

effi ciency, whether

in buildings, factories,

infrastructures or

dwellings. We also supply

products and solutions

exceeding environmental

compliance requirements.

Particularly, for the

cement industry, we

recommend an energy

audit to improve energy

effi ciency. We help

to set up control and

management solutions

aimed at reducing

customer energy

consumption by up

to 5%.”

Improved security

For an industry such as cement, electrical distribution

systems must offer a high level of protection for the

security of your employees and your equipement.

They should be particularly rugged and reliable,

operate 24/7 in a diffi cult environment, and be safe

when undergoing routine maintenance operations.

The same is true for advanced automation systems,

which must assure process operating safety and

guarantee optimum work and safety conditions.

11

l Design new cement plants at minimum cost

l Improve quality and productivity

l Optimise energy performance

l Contribute to Sustainable Development

12

Mix optimisation and

raw material quality.

Energy monitoring

and control.

Hi-performance

speed-drives.

Energy monitoring

and control.

Hi-performance

speed-drives.

S c h n e i d e r E l e c t r i c s o l u t i o n sReduction of heat losses

by controlling airfl ow,

temperature, pressure

and energy materials

balance.

Measurement and

control of consumables

in the combustion

process

Hi-performance

speed-drives.

13

Gas emission control

and monitoring.

Permanent monitoring

by fi nished product

analysis for optimum

quality.

Energy monitoring

and control at clinker

grinding.

Hi-performance

speed-drives.

Flexible control

architectures,

structured engineering

tools and libraries that

reuse the best practices

for design of new

factories, site

modernisation or

extensions.

Management of

production to improve

adjustments, quality

controls and process

outputs.

Plant energy

management and

monitoring at each

process phase.

Gas emission

management.

Permanent supervision

on line.

Historic data and

reports.

The purpose of our solutions?

To offer you a complete solution to all

issues relating to design, development

and trouble-free operation of your

production sites. Globally monitored,

the process gains in performance,

enabling each at their level to work better

and with complete confidence…

14

Knowle

dge Based S

ystem

s

Electrical

Distributio

n

Energy

Managem

ent

Critical

Power

IMCC

MES

Autom

ation

Power

Supervisio

n

Process

Control

Network

s

Devices

Objects

Database

VariablesLib

rary

Services

S c h n e i d e r E l e c t r i c s o l u t i o n sFrom electrical distribution to MES,

our solutions integrate the highest

performance tools on the market.

Developed by our R&D teams, they are

complementary and designed to simplify

the work of your designers and improve

your productivity at all levels of the

cement plant.

15

Time can be on your side if you use all the resources available to you to reduce project

development lead times.

With this in mind, we have designed typical automation and control architectures

depending on process complexity and your daily output.

They cover the complete production process and adapt to your specifi c requirements

and expectations in terms of installation, production and maintenance.

They are tested and validated. You can use them with assurance of total security.

MES

Asset Management Operator working station Remote OWS

SCADAservers

Instr

um

en

tati

on

Instr

um

en

tati

on

Instr

um

en

tati

on

Instr

um

en

tati

on

Instr

um

en

tati

on

Instr

um

en

tati

on

Historianserver

Kiln scanneranalyzer

Vibration

Internet

Packing

Blendinganalizer

Quality Control Room

Blending control, Kiln optimization, Finess control

Control Room

Quarry & crusher Raw mill 1, 2,… Fuel mill Kiln 1, 2,… Cement mill 1, 2,… Electrical Distribution

Typical cement control system architecture (5,000 to 10,000 tonnes/day)High performance and profi tability.

T y p i c a l c e m e n t p l a n t a r c h i t e c t u r e s

16

Total integration in your environment

The Schneider Electric solution uses powerful control system solutions associated

to integrated engineering and programming tools.

Combining innovation and power, this platform responds to critical demands

of the cement industry:

- use of the highest performance equipment in its category offering high availability

functions (redundant systems required for certain kiln applications),

- process control and advanced mathematical functions (enabling certain expert

functions without external tools),

- process simulation (off line) without risk of actual operation, saving time and cost

in commissioning, plant expansions or process improvements/modifi cations,

- fl exible programming languages covering both process engineering and

the demands of electrical and maintenance teams.

Integra

ted O

bject

Documentation

Control O

bject

Supervision

graphical object

In choosing Ethernet, we favour

openness and integration

Why use a proprietary communication network when

Ethernet offers all the performance and security

required by critical applications?

You no longer face diffi culties in integrating

specialised third party equipment in our automation

systems: expert and optimisation software, weighing,

gas emission systems, vibration control, kiln scanning

systems, network instrumentation fi eldbuses

(Profi bus, Modbus, Hart and Foundation fi eldbus).

Site

Kiln

preheater

Kiln

Temperature

control

Instrument

A real view of your process

The increasing complexity of factory engineering

imposes optimisation of the design phase by

modelling an object-oriented structure depending on

the real sequencing of the process.

Our advanced design and generation software tool

integrates numerous controllers and supervision

systems in a common database.

It structures the factory application according

to the process functional diagram and delivers

a true distributed control system environment that is

fl exible and open.

“Process control” and “Cement” dedicated object

libraries are also available. They enable savings

in development costs and can be reused for site

extensions or design of new factories.

Powerful tools structure and

organise the automation

application according to real

sequencing of operations

execution.

Common object

database creation.

P r o c e s s o p t i m i s a t i o n a n d c o n t r o l

17

The power of Ethernet and the Web

Web servers integrated in the PLC enable remote

access to automation and control equipment using

a simple navigator.

You can create custom Web pages reproducing

the structure of equipment or the process and you

monitor and when necessary, control its operation.

In the case of events, mail servers automatically

generate messages to operators concerning

variables or alarms.

Asset management from instruments and other

units (for example motor protection relays) is also

possible at any point in the Ethernet network.

Custom pages embedded

in the equipment reproduce

process screens.

F a c t o r y c o n t r o l a n d s u p e r v i s i o n + M a i n t e n a n c e t o o l sTotal control of your production

Supervision and control tools enable simple,

complete and transparent access to fi eld variables.

They offer user-friendly graphic display of all this

information. Your operator therefore has a clear

view of the process which enables defi nition and

implementation of actions to optimise productivity.

Performance of our supervision systems is improved

by use of multi-CPU or hyperthread technology

machines.

At startup, the system is automatically able to

create separate components across multiple CPUs,

resulting in improved performance and stability.

Confi guration modifi cations are achieved with

minimum interruption.

W e bs e r v e ri n s i d e

18

Dedicated modules

for your environment

Metrics

You calculate and control key indicators in real

time: total energy consumption, total fuel

consumption, quarry and plant energy effi ciency, raw

materials use vs. amount of cement manufactured,

gas emissions, etc

Production

You view the image of your process by integrating

all variables: raw materials, consumables, energy,

waste, emissions, rejects, etc.

Quality

You control quality of your products throughout the

production cycle. You monitor product conformity

by integrating data from your LIMS (Laboratory

Information Management System) and from on-line

analysers: basic mix formulation, kiln supply particle

size, mineralogy control, cement particle size.

Downtime

You analyse production downtime causes in precise,

categorised and and user-friendly automatic reports.

Tracking

You follow your production: dates/product type/

packing information.

Maintenance

You plan and monitor maintenance operations:

equipment use, execution times, number of

starts, load factors.

Cost

By comparing cost and line production information,

you assess factory performance. You anticipate

trends and take decisions based on real time data.

You can also compare data using your fi nancial

management software.

Logistics and Accounting

Suppliers Production

Plant IntegrationSCADA, OPC, Historian, LIMS, Manual

Business IntegrationISA-95, B2MML

Customers

MES Integrated User Experience

Management,Reporting

Planning,Operating,Informing

Enterprise Portals

SharePoint, SAP,

HTML-Based

Generic Visualisation

Analysis Client,

Reports

Custom interfaces

SharePoint, SAP,

HTML-Based

Datarepository

Historical Data

Historian

Enterprise Portals

SCADA

3rd Party Databases

Quality, Document

Management Systems,…

Algorithm

Processing

MES

M a n a g e m e n t t o o l s ( M E S * )

* Manufacturing Execution System

19

Planner

You integrate your ERP in factory environment tasks:

production orders, maintenance activity, wait times.

Knowledge

A repository for documents and data that

summarises relevant production process information:

production incidents, important information, general

production data

Historian tools

All factory equipment generates data. But this data is

of no value unless correctly collected and analysed.

The Historian software solution assembles data from

multiple information sources and, in association

with MES systems, generates detailed reports and

data helping decision-making.

Thanks to the openness and fl exibility of our solutions, connectivity between

automation systems and gas emission monitoring systems becomes simple.

Equipment with basic communication functions is easily integrated using an

Ethernet router and customisable Web server.

In this way you have access to the gas emission system and control its correct

operation with the help of graphics generated with a standard Web navigator.

And the server e-mail function can alert you to any important event.

All information collected from this equipment interacts with factory supervision

and management systems to monitor, generate reports and, most importantly,

take actions in real time.

G a s e m i s s i o n r e d u c t i o n

20

An imperative, reduce

your energy consumption

Our “energy effi ciency” solutions are based on a

global and progressive approach.

Global, because they are aimed not only at

consumption reduction and cost optimisation but

also at energy reliability, availability and quality.

Progressive, because, our systems are easily

expanded and upgraded according to new plant

requirements due expansions or improvements.

A valuable ally in energy saving and

production shutdown reduction

Our IMCC (Intelligent Motor Control Center) solutions

use the best network architectures, motor protection

and variable speed drives.

IMCC brings intelligence to motor control:

- system availability based on networks with fewer

potential failure points,

- fewer shutdowns thanks to remote access

and improved problem identifi cation,

- more information available to aid effective

decision-making,

- energy savings by use of high-performance variable

speed drives,

- fl exibility of solutions based on multiple networks.

E n e r g y e f fi c i e n c y

A high-performance

management system

Our Energy Management System integrates software

and hardware solutions operating on Ethernet

networks, where can be distributed throughout

a factory or over all installations of a multi-site

enterprise.

The system permanently monitors key points of the

electrical distribution network as well as equipment

and material. It delivers relevant information to those

who need it, wherever they are located.

The combined use of MES (Manufacturing Execution

Systems) with the energy management system

enables effective decision-making. Together, they

offer quick and quantifi able return on investment,

often after only a few months.

The system is highly fl exible and adaptable to your

environment and your normal working procedures.

In particular it offers:

-the world’s most highly developed energy-linked

instrumentation,

- modular equipment easily adaptable to your site

developments at minimum cost,

- embedded memory to avoid data loss,

- compliance with industrial standards and

international certifi cations,

- creation of energy quality compliance reports,

- low installation and TCO costs.

21

Systems and solutions

Network UPS,

Desktop UPS

Low end UPS systemsTVSS - Transient Voltage

Surge Suppressors

Data centers & facilityMainframe, data centers,

facility control room

Control roomServers, routers,

networks, desktops

Plant floorPowering devices

equipements, processes

A permanent operation

reliability approach

When planning your cement plant, it is essential

to precisely analyse your requirements and anticipate

future developments so as to make the right electrical

installation design choices and to avoid undersizing

equipment.

Schneider Electric is the worldwide leader in

Electrical distribution, providing best-in-class

solutions for the most exigent requirements:

- protection and control of LV power circuits,

- MV secondary distribution products,

- MV components,

- MV/LV equipment and systems.

Secured energy

For the most critical parts of the process, the use

of uninterruptible power supplies (inverters) and/or

generator sets is the only way of avoiding all risk

of production shutdown.

Our high-power uninterruptible supplies are

recognised for their qualities and ease of integration

in any industrial high-performance electrical

distribution system. They integrate control and

supervision functions enabling operation

self-monitoring, battery state indication, etc.

Uninterruptible power

supplies for all enterprise

levels: from simple control

devices to large power

supply systems and complex

IT solutions.

Be protected against possible electrical supply failure and assure

quality and availability of electrical energy.

E n e r g y d i s t r i b u t i o n a n d C r i t i c a l P o w e r

22

Advice and expertise

Need a new method, or skills on a point

considered particularly important?

Our experts and consultants offer to help you

analyse what exists and to defi ne and deploy

specifi c solutions.

For operation

In operations or preventive maintenance, our

tools and methods enable you access to accurate

diagnostics from our systems: electrical distribution

equipment, intelligent motor control centers,

communication networks, speed drives, process

control systems. In case of intervention, a detailed

and commented report is provided following our

technical visit.

For modernisation and new projects

- At pre-project, our consultants help you assess

opportunities, defi ne solutions, estimate budgets

and propose deployment techniques.

With diagnostics, recommendations and results

of feasibility studies, you validate and secure

your project.

- For project steering, our experts provide

support in preparing specifi cation studies (software

standardisation, architecture diagrams, etc.),

assistance on solution deployment and results

checking.

Project management

Looking for commitment on our part for your

modernisation projects and new plants? You can

count on the experience and involvement of our

teams and the support of our partners.

Using the specifi c tools we have developed

(engineering and design software, migration tools

and dedicated libraries), production shutdowns are

restricted to the minimum.

We help you improve the plant performance,

proposing solutions for the modernization of your

current control and electrical distribution systems and

providing solutions for your new installations.

And we can provide longer term support by:

- handling design and deployment of a standardised

solution and tools on a project that can be applied in

other sites,

- associating maintenance of the installed base with

planned modernisation.

A c o m p l e t e r a n g e o f d e d i c a t e d s e r v i c e s

Schneider Electric

training centres

worldwide

23

Training

Does safety of your operation and plant

performance depend on constant adaptation of

the skills of your personnel? We can help you:

Identify your training requirements by systematic

analysis of levels and functions of your teams,

propose training modules covering your installed

automation equipment, follow up acquisitions

by ongoing training, offer training modules designed

to suit your timing and locations.

You have available over 50 training centres with

high technology learning tools, professional trainers

expert in both industry and teaching, standard or

customised courses on-site or on our installations.

Replacement parts and repairs

Does your competitiveness depend on

your reactivity to breakdowns and malfunctions?

We can help you limit downtime periods.

From our stock we can supply you with tested and

certifi ed replacement parts compatible with your

installed equipment.

By contract you can stock on your installations

replacement parts which remain as our remote stock

until be effectively used.

Finally, you have also available a strong distribution

channel network, present worldwide, that opens to

you another access point to our products.

Maintenance contracts

Do you count on long-term reliability and

performance of your installations? Let’s build

together your custom services contract.

Services pack or made-to-measure:

- telephone support for priority access to our experts

centre,

- web access to benefi t from latest version software,

- stock of our branded replacement parts on

your installations or in our warehouses,

- assurance of on-site assistance within a guaranteed

time.

We help you anticipate technical risks and perform

essential modernizations by taking account of

equipment obsolescence. It avoids penalizing

production shutdowns. You control maintenance

costs by optimised replacement parts stock

management.

Operation

Modernisation

operating people

dedicated solutions in

the world

43-45 Bd. Franklin-Roosevelt

F-92505 Rueil-Malmaison

FRANCE

Tél. : +33 (0) 1 41 29 70 00

www.schneider-electric.com

Due to evolution of standards and equipment, characteristics indicated in texts and images

in this document are binding only after confi rmation by our departments.

Publication: Schneider Electric

Design: pemaco

Photos : Médiathèque Lafarge - Hamilton De Oliveira, Jean-Philippe Mesguen,

Nian Zeng, Christelle Bitouzet, José Antonio Rojo, Samuel Ashfi eld, Alam Beg Imtiaz

Print:

03/2008

Schneider Electric Industries SAS