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Più affidabilità ed efficienza: così si rinnova il cementificio

La produzione del cemento richiede grandi quantitativi di energia, oltre che di materie prime. Nello stabilimento di
Merone (Como) del gruppo Holcim un intervento di adeguamento impiantistico realizzato con la collaborazione di ABB ha migliorato il processo e ridotto i consumi energetici ben al di sopra delle aspettative.
Azienda leader
Fondato nel 1928, il cementificio di Merone è stata una realtà storica nel campo dei materiali per costruzioni. Nel 1996 è stato acquisito dal gruppo svizzero Holderbank, che ha assunto il nome di Holcim dal 2001, e oggi fa quindi parte di uno dei maggiori gruppi mondiali nel settore del cemento, con 80 mila dipendenti in 70 Paesi.
In Italia Holcim produce cemento in tre stabilimenti: Merone e Ternate (Varese) comprendono la fase di cottura e sono a ciclo completo, mentre Ravenna è centro di macinazione.
Tradizionalmente il mestiere svolto da Holcim (Italia) consiste nella produzione di cemento ma, negli anni, l’attività è stata estesa alla produzione di altri materiali da costruzione come gli aggregati (sabbia e ghiaia) e il calcestruzzo, divenendo così un Gruppo fortemente integrato e una realtà industriale importante del Nord Ovest d’Italia.
La posizione strategica sul territorio è il principale vantaggio competitivo di Holcim, unico operatore del settore in grado di servire il mercato della Lombardia con cemento, aggregati e calcestruzzo.
Parallelamente alle attività di espansione l’Azienda ha accresciuto inoltre le proprie competenze tecniche ed avviato un percorso di sviluppo sostenibile per coniugare crescita economica, responsabilità sociale e tutela dell’ambiente.
Un forno strategico
Il cemento è prodotto attraverso la macinazione e la miscelazione di clinker e di correttivi (gesso, calcare, loppa, pozzolana). Il clinker è il semilavorato base e si ottiene mediante la cottura in forno di una miscela di materie prime
(calcare e argilla) a elevata temperatura (1450 °C). A Merone

esistono due forni, numerati rispettivamente 4 e 5, dei quali attualmente solo il primo è acceso: il calo della domanda legato alla crisi economica ha infatti determinato lo spegnimento del secondo nel 2009.
Attivo a ciclo continuo, il forno 4 perciò è strategico per lo stabilimento. L’impianto risale agli anni 60 e ha subìto modifiche negli anni 80, relative però alle sole parti meccaniche. La parte elettrica, ormai molto datata nell’impiantistica, comprende quattro motori elettrici principali: i tre di taglia maggiore servono per la ventola principale, per il ventilatore filtro e per la rotazione del forno. Un quarto, di taglia minore, è impiegato invece sulla ventola per il recupero termico. Tutti i motori erano in c.c. perché al tempo della costruzione del forno ancora non esisteva la possibilità di regolare la rotazione dei motori in c.a. tramite inverter.
La vita utile dell’impianto si avviava ormai ad esaurimento: la tipologia dei motori e la loro età avanzata richiedevano infatti prolungate e frequenti fermate per la manutenzione delle spazzole delle tre macchine principali. Questi interventi, della durata di quattro ore ed effettuati ogni mese e mezzo, comportavano significative perdite di produzione, pari a 400 tonnellate di clinker per fermata.

A orientare le scelte verso ABB sono state l’ affidabilità delle apparecchiature, la disponibilità delle parti di ricambio e la familiarità che il personale Holcim ha maturato nel tempo con questi prodotti.

L’intervento
Dalla situazione descritta è scaturita quindi la decisione di sostituire tutti i motori con apparecchiature più moderne
- installando inverter e motori in c.a. in sostituzione del ponte di alimentazione in c.c. - e di rifare integralmente la cabina elettrica: alla luce dei vincoli di budget, l’intervento è stato programmato in step successivi da realizzare in tre anni.
La prima fase prevedeva la sostituzione del solo motore del ventilatore principale (1.400 kW) ma un guasto ed evidenti segnali di stress del motore del ventilatore filtro (800 kW) hanno indotto a procedere in contemporanea anche su questo. Gli accordi siglati con ABB e la piena collaborazione dell’agenzia D-Tec hanno permesso di anticipare le consegne rispetto ai tempi previsti .
I nuovi motori sono della serie AMI, nati per la MT ma riavvolti in BT, fabbricati nello stabilimento ABB di Helsinki.
Per gli inverter si è optato per gli ACS 800 a basso contenuto di armoniche.
I vantaggi
Dopo la messa in servizio, sono state effettuate le misurazioni per quantificare i vantaggi assicurati dal nuovo impianto.
L’attesa era che l’apporto più consistente derivasse dalle necessità di manutenzione sensibilmente ridotte e quindi dall’aumento della produzione annua, puntualmente ottenuto.
I risultati sono però stati superiori al previsto: si è infatti constatato che il passaggio ai due motori in c. a. con inverter, unitamente ai nuovi impianti in cabina, assicura una riduzione degli assorbimenti molto significativa, pari a oltre 1.500.000 kW all’anno. I tempi di ritorno dell’investimento, che erano stimati in tre anni calcolando solo le fermate, si sono sensibilmente accorciati.

ABB e il cemento: una grande esperienza
La supervisione del forno è affidata a un sistema di controllo e gestione Expert Optimizer di ABB, che modula in automatico i parametri della produzione permettendo di ottimizzarla.
Proprio lo stabilimento di Merone è stato scelto, quasi trent’anni fa, per l’installazione del primo prototipo di questa tecnologia di successo, da allora costantemente aggiornata.
Durante la fermata del forno sono stati installati anche due inverter più piccoli del tipo ACS 800 su motori da 90 kW dell’impianto di trasporto e dosatura del carbone, principale combustibile utilizzato dai bruciatori. La velocità di trasporto era in precedenza regolata con mezzi meccanici e richiedeva la fermata dell’impianto per essere modificata.
Sono ABB anche i sistemi di monitoraggio delle emissioni al camino che, grazie alle ottime performance dell’analizzatore
ACF-NT, garantiscono una disponibilità superiore al 95 per cento.
Vale la pena infine di ricordare che all’inizio del 2011 ABB ha siglato con Holcim un accordo per l’installazione presso il cementificio a Untervaz, in Svizzera, di un nuovo sistema per la produzione di energia elettrica recuperando calore dai gas di scarico a bassa temperatura.

ABB S.p.A.
Discrete Automation and Motion Division
Via Luciano Lama 33
20099 Sesto S. Giovanni (MI)
Tel.: 02 2415 2999
Email: energy.efficiency@it.abb.com www.abb.it/energyefficiency Ci riserviamo il diritto di apportare variazioni tecniche o modificare i contenuti di questo documento senza preavviso. Sono vietate la riproduzione e la diffusione, anche parziali, dei contenuti di questo documento, sotto qualsiasi forma e con qualsiasi mezzo – elettronico, meccanico, copia, registrazione o altro – senza il previo consenso scritto di ABB.
© Copyright 2011 ABB. Tutti i diritti riservati

CN_Holcim/gen 2012

Più affidabilità ed efficienza: così si rinnova il cementificio

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