Implementation of continuous emissions monitoring system (CEMS) in Dalmacijacement, Croatia

Automation & RoboticsProjectsSouth-East European INDUSTRIAL Мarket - issue 1/2012

Dalmacijacement d.d., of Kastel Sucurac, Croatia is part of the CEMEX consortium, one of the top building materials companies in the world. The company is the Croatian market leader in cement production, with three factories (plants): Sveti Juraj (Saint Juraj), Sveti Kajo (Saint Kajo) and Kolovoz.

Project Summary
The Republic of Croatia, in cooperation with The European Union, has recently introduced legislation for environmental protection through continuous emissions monitoring. Dalmacijacement d.d. set out, with assistance from ECCOS inzenjering, to bring all of its factories under compliance, with the goal of creating a continuous emissions monitoring system (CEMS). Manufacturing facilities are often assumed to be sources of pollution, so a system was required that could continuously monitor the emissions, graphically depict current emissions, normalize the measurements, archive measured and calculated (i.e. normalized) values, inform the public through corporate Web pages and, most importantly, create daily, monthly and yearly reports in Microsoft Excel and XML-formats that adhere to the legislative requirements.

ICONICS Software Deployed
Dalmacijacement d.d., working with systems integrator, ECCOS inzenjering, selected ICONICS’ GENESIS32Ù Web-enabled, OPC-integrated HMI/SCADA Suite (including GraphWorXÙ32, AlarmWorXÙ32 and TrendWorXÙ32 components), as well as the BizVizÙ Manufacturing Intelligence/ Business Visualization Suite (including the ReportWorXÙ enterprise reporting/charting/analysis component).

The newly created system collects raw (i.e. measured) values and recalculates them to create normalized data based on the normalization factors. Both raw and normalized values are presented to the operator through ICONICS GraphWorX in real time. If any of the measured values exceed the defi ned upper limits, an alarm is triggered via AlarmWorX, informing the operator to change the process in question. Any other malfunctions or errors in the equipment also trigger alarms, which are depicted in GraphWorX and stored to a database via AlarmWorX logger.

Data is stored to a SQL database through ICONICS TrendWorX. Since the project has to satisfy people in different positions and with different interests, data is stored in three logging groups; 1 minute; 10 minute; and 30 minute average values. The first two groups are important to the operators at the factory (real time) and to the public through corporate Web pages (slight delay). The third group (30 minute average values) is needed to create reports for the Croatian environmental agency. Reports are created through ICONICS ReportWorX, a component of the BizViz suite.

Considerable SQL programming (Stored procedures, Dynamic SQL) had to be done due to the fact that the measured values had to be positioned on exact positions in Excel sheets (48 half-hour values per day - if one is missing or corrupt, the Excel cell has to be empty) as well as verified (Kiln On/Off, Main generator On/Off, Transition period or normal operation mode).

Benefits of the System
Dalmacijacement d.d. selected ICONICS for its emissions monitoring system upon ECCOS inzenjering’s recommendation. The ICONICS solution helped meet the building materials company’s requirements for cost-effective data visualization, control, alarming, trending and reporting. The system integrates with the company’s Siemens S7/300 modular controllers, SIMATIC ET200 I/O systems, Profibus communications and a number of specialized sensors including AirLoq gas analyzers, Flowsic 102 flow monitors, RM210/FW101 dust monitors and Itabar particle analyzers. ICONICS solutions also integrate with Dalmacijacement d.d.’s Microsoft software, including Windows Server 2003 R2, Office 2007 (especially Excel) and SQL 2005 Express Edition SP2.

Dalmacijacement d.d. is pleased with their new driven emissions monitoring system and plans to use ICONICS for further development encompassing additional pollution factors throughout its sites, while ECCOS inzenjering plans to use a similar system for other clients requiring the same level of emisisons monitoring, including other factories, electric plants, waste processing facilities and more.