Sinjar Cement Plant Automation

  • Customer:Sinjar Cement
  • Category:Process
  • Date:-
  • Status:In Commissioning
  • Application:Cement
  • Control System:ABB Freelance DCS
  • Size:18 controllers & 20.000 I/O

Project Details

After several years of operation, the new owners of the Sinjar plant who is Kar Group decided to modernize the plant.

Main targets of the project are to reach a plant production capacity of 1.8Mt/year and operate the plant continuously at the targeted production capacity after completion of the rehabilitation.

They also target to minimize the environmental impact of the plant by use of modern equipment.

  • Two crossbar coolers (3500t/day each)
  • Six cooling air fans for each cooler
  • ESP filter for each kiln line
  • 10 new jet-pulse type bag filters
  • 4 raw mill fans
  • 4 raw mill / kiln clean gas fans
  • 4 preheater (ID) fans
  • 2 clinker cooler clean gas fans
  • MV or VF drive units for main crusher, raw mills, recirculation fans, ID fans, clinker cooler clean gas fans and cement mills
  • 22 slip ring drives for constant speed including all necessary liquid starters
  • 12 variable speed drives
  • Dosing belt weighers
  • Belt weighers
  • Flow meters
  • Truck weighing bridges
  • 2 kiln shell scanners
  • 2 infra-red kiln camera system
  • Fuel oil supply system for kiln line 1
  • High pressure filter/pump station
  • Preheater station
  • Valve train for calciner burners
  • Kiln burner and valve train for kiln burner
  • 50 shock blowers

Both the cement lines are controlled with ABB’s Freelance DCS platform. There are 18 controllers in the system, 12 operator workstations and a capacity of approximately 30,000 soft and hardwired I/O. All the commissioning was done and completed remotely over Internet.