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Home / Industries / Lime and Cement

Lime and Cement

Universal Dynamics has served the lime and cement industries for over 25 years specializing in process and productivity solutions. We are the leaders in the application of kiln controls and instrumentation having worked on more than 40 rotary kiln projects. Our objective is to develop innovative methods for increasing production and quality.

Our experience is unmatched in the design and commissioning of electrical, control and instrumentation systems for rotary and vertical lime kilns as well as dryers, preheaters and rotating hearth furnaces. Drawing upon a wide range of resources that include knowledgeable staff in the areas of chemistry, metallurgy, engineering (electrical and mechanical), software development and management consulting, Universal Dynamics offers a wide range of services including:

  • Feasibility and plant optimization studies
  • Project management services
  • Process and instrumentation conceptual and detail design
  • Electrical engineering such as power and energy management, substation design, distribution systems plant electrical design and layout and variable speed drives
  • Control system design and implementation for programmable logic controllers (PLCs), human-machine interfaces (HMIs), distributed control systems (DCSs), custom software and advanced controls
  • Quality, environmental and safety management
  • Construction supervision
  • Startup and commissioning

Extensive knowledge of the Lime and Cement industries has led Universal Dynamics to develop innovative technologies such as:

  • KilnMax™, our universal kiln automation system, is just one of the innovative technology products that we have developed for the pyro-processing industries. Use the BrainWave® adaptive model-based controller and our Expert Systems technology to automatically adjust the kiln set points for optimal kiln operation. KilnMax can reliably control your process improving quality, production and fuel efficiency. Variable feed characteristics, long process delays and non-linear combustion and calcination can all be effectively managed.

  • CrushMax™ is a computer and PLC based control system that automates and optimizes crusher operation using custom level sensors, video imaging and custom programming routines to minimize bridging in feed hoppers. Benefits of CrushMax include manpower reduction, uniform crusher loading, and increased throughput.

  • The TMT Kiln Simulator is a PC-based lime kiln process simulator based on the thermodynamic mass tracking principle. This simulator was initially developed for testing and verifying advanced kiln control strategies but has also proven useful for the validation of PC/PLC based controls, operator training and predicting outcome of planned process or equipment changes.

Related Literature  

Articles/Papers

  • KilnMax™ brochure  (PDF)
  • An Expert System Application for Lime Kiln Automation   (PDF)
  • Fan Drive System Efficiencies  (HTML)  (PDF)
  • Microwave Cooler Level Control  (PDF)

Sample Projects

  • Carmeuse Pennslyvania Inc., Annville, PA: Automation of a Multiple Kiln Plant   (PDF)
  • Productivity Improvements at Cricket Mountain  (HTML)  (PDF)