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SOLUTIONS | Aspiralli AG

APCS of Concrete-Mixing Plant

Automation of concrete-mixing plant (CMP) provides the following solutions:

– Control system replacement or upgrade for a concrete plant with outdated management systems, such as Betonmatic, МСУ СБ, etc.;

– Adaptation of existing control systems to the customer’s requirements as well as in case of any change in the main equipment;

– Development of the control system that integrates autonomous mechanisms of a concrete plant furnished with local automation.

The concept of automated control systems for concrete plants is based on the idea that one person must operate a plant and concrete trucks traffic with ease. Therefore, plants are equipped with microprocessor automatic control system except for the control panel manually operated.

General description of a concrete mixing plant

A concrete mixing plant consists of:

– System of inert materials loading;

– System of inert materials unloading, which occurs through sector valve using vibrators located on bins of inert materials.

– Cement silos;

– Batcher for inert materials, load cell weighing sensors per a conveyor or weigh hoppers;

– Cement batcher, load cell weighing sensors to the hopper;

– Water batcher, water supply through magneto-inductive flowmeter or load cell scales;

– Chemical admixture dispenser, chemical admixtures supply through magneto-inductive flowmeter or load cell scales;

– Concrete mixer for high-quality components mixing at fast rate.

Concrete mix unloading is ​​performed through the discharge funnel directly onto the concrete mixer truck or tip lorry.

Inert materials loading can be directly into the bunker for inert materials storage or onto inclined conveyors and vertical elevators.

Cement is loaded by special loading equipment.

Chemical admixtures are delivered in appropriate containers or bags and then adjusted to proper consistency directly on the site.

Cement, water and chemical admixtures are proportioned in respective batchmeters, then fed into the concrete mixer, while a dose of inert materials is fed by the conveyor belt or in a charging ladle.

From a functionality point of view a CMP (concrete mixing plant):

– proportions and feeds inert materials into the concrete mixer;

– proportions and feeds cementing agents (cement, ash, etc.) into the concrete mixer;

– proportions and feeds water into the concrete mixer;

– proportions and feeds chemical admixtures, ice, liquid pigments, etc. into the concrete mixer;

– produces and conveys the concrete mix onto concrete mixer trucks and dump trucks for transporting.

The concrete mixing plant consists of:

– Inert materials receiving hoppers, which can be located below zero level for immediate loading onto trucks and can be loaded using a wheel loader from a ramp or with inclined conveyor.

– Weighing hoppers or weigh belt conveyors used for inert materials weighing. They are located under receiving hoppers equipped with sensors.

– Dosing belt conveyors giving more accurate dosages of inert materials fine fractions.

– Cement and additional components warehouses consisting of vertical silos of various sizes are used for cementing components and mineral admixtures storage. Materials are fed into the cement mixer by a screw conveyor located in bottom silos through cement dispenser or by pneumatic conveying system.

– Measuring dispensers usually located above the concrete mixer onto a support structure connected with the mixer support. Dispensers are used for water, cement and chemical admixtures measuring.

– Concrete mixer is located on the supporting structure and used for components mixing to prepare concrete mixture.

– The control panel comprising the automated process control system that is controlled by the computer program installed in the computer and PLC controller. An operator can intervene in the process at any time and control the concrete production.

– Piston or screw compressors are commonly used in pneumatic systems, air is suppled to cylinder actuators mounted on jaw receiving hoppers, water and cement batchers as well as inlet and outlet valves of chemical admixture. Aeration of bulk materials in silos is performed with a silo blower. Compressed air is also used for self-cleaning air filters located on cement silos.

Concrete mixing plant is equipped with interconnected floors and stairways, guards and handrails to prevent accidents occurring when performing maintenance.

The control system is intended to work in two modes: manual (adjustment) and automatic. In manual mode various instruments as indicators and controls are designed to monitor the process control operation, they can be mounted on the controller front panel and consoles set in place. Recipe control in concrete production is implemented manually to monitor precise weight by transducer weight indicators. In automatic mode all operations relating to concrete preparation are automated as for one downloaded from AWP (or touchpad) to the recipe batch controller. When operating in the automatic mode the operator can select manual mode to add water into a mixer in order to achieve concrete plasticity and perform manual unloading of the ready-made mixture onto a concrete mixer truck or a dump truck.

While working in operator’s AWP data archiving is done to secure and store data and reports referring marketed output are generated.

With state-of-the-art software specifically designed for concrete mixing equipment you can control your process to perfection. It is possible to configure the list, offering input and output signals of the controller as well as tuning agility of control algorithms.

The software includes the following set of video frames on the operator’s panel:

  • Basic video frame;
  • Filler dispenser;
  • Cement batcher;
  • Water batcher;
  • Chemical admixture dispenser;
  • Mixer;
  • Settings – general of crack safety;
  • Filler settings;
  • Cement batcher settings;
  • Water batcher settings;
  • Admixture dispenser settings;
  • Mixer settings;
  • Workshops configuration settings;
  • Parameters of filler weighing scale;
  • Parameters of cement weighing scale;
  • Parameters of admixture weighing scale;
  • Parameters of water weighing scale;
  • Humidity parameters;
  • Wattmeter parameters;
  • Create/ change recipes;
  • Creating assignments;
  • Report on production and aggregates consumption;
  • Alarms;
  • Utilities (including diagnostic of crack safety).

 It is time-proven experience in automatic control engineering of workshops Wetbeton, SuperMobyMix, MobyMix, ПМЧ-90, Pataud, СБ-145, СБ-164 etc.


APCS of Cement Production and Packaging, Automation of Grinding Units

Large cement companies in Ukraine and CIS countries are major cement players controlling substantial market share, but their extremely energy-intensive and inefficient manufacturing processes can lead to losses due to the use of ball milling. Manufacturing processes start-up as well as technological changes of work cycles at such enterprises takes considerable time, up to several weeks. Moreover, in general, the cement works equipment is deteriorated for the moment.

Modern cement plants with medium and low cement manufacturing capacity are applying best practices and completely new innovative technologies, first of all cement and raw materials grinding. These technologies are based on drum roll crushers use, their application leads to significantly higher efficiency than existing ball mills.

An automated control system plays a vital role in the cement industry performing operations with greater conformity oriented towards high-quality end products with maximum work output. It is almost as quick as a one-click, it optimizes the process by retargeting operational procedures and focusing on various cement brands as well as blending different raw materials.

Key functions of APCS:

  • manual and automatic control of all operations in a technological cycle at raw materials department, calcinating shop, storage of raw materials, cement grinding shop, ready-made product warehouse and packaging department;
  • execution phases of a mission profile of starting and stopping processes;
  • adherence to predetermined standards of the output high quality performance;
  • quality control of incoming raw materials and finished products, workability of processing conditions, failure prediction to prepare better for emergency situations;
  • end to end accounting of raw materials and finished products at all stages of the manufacturing process.

Cement manufacturing processes are controlled using highly reliable operator panels with graphic displays showing the status of currently running processes.

 Virtual machine control panels are used to control and configure the process equipment settings providing visual and informative data representation of each mechanism.


APCS for Furnace Gas Cleaner

Principal production processes:

  • Gas-air mixture sampling from each electric furnace and its cleaning in bag filters;
  • Regeneration of filter sections;
  • Pneumatic conveying of collected dust from filter section bunkers to general dust collecting bins;
  • Dust discharge from hoppers.

Key functions of the system:

  • automatic measurement of process parameters and control of signal integrity from analog sensors;
  • automatic reception of digital signals like “dry contact” by relay switch sensors running on 220V AC 50Hz and control of the signals integrity;
  • actuators accept signals from the control system automatically;
  • automatic adjustment (stabilization) in accordance with Pid-law of smoke sucker output by current load balancing of motors via guide vanes of respective smoke suckers;
  • automatic balancing, shock-free switching on and bumpless transfer when control modes are changing and settings allow changes to the control mode (closed/open loops);
  • actuator values are automatically recorded (free plays, delayed start and stop etc.);
  • automatic control of parameters change in given technological limitations and signaling system (including acoustic alarm) with values of controlled parameters during an emergency;
  • regulatory control over transient time;
  • automatic locking and/or regulator and other equipment changeover to work safely in case of emergency;
  • modify the process tasks, control loop settings and other configurable options remotely;
  • Automatic and remote control of filter regenerating mechanism systems, dust unloading system from dust collector system to disposer hoppers;
  • Automatic and remote control of all the system motors, valves and gates;
  • Displaying current parameter values represented in video frames, data graphical display with arbitrary scaling;
  • Archiving of all measured parameters data, recording of events and operator’s actions being able to access an archive at any time;
  • Automated data exchange between disparate systems.

Types of system video frames

  1. Control panel ;
  2. To read data in mnemonic diagrams:
  • Basic mnemonic diagram;
  • Mnemonic diagram of dust pneumatic conveying system;
  • Mnemonic diagram of current values of measured parameter change;
  • Mnemonic diagram of gas-air mixture sampling;
  • Mnemonic diagram of regeneration of electric furnace filter sections;
  1. Service videos:
  • Watch history video in graphic form;
  • Event viewer to view event logs;
  • Video buzzer controls;
  • Data viewer for viewing diagnostic data;
  1. Control effects:
  • Objects tools of relay type (valves, gates, sluice feeders, vibrators, smoke suckers) ;
  • Filter section controls;
  • Control loop performance management;
  1. Control system maintenance:
  • Meteorological data visualization;
  • User registration in video frame;
  1. Settings:
  • Videoframe of configuration of passport parameters to be measured;
  • Videoframes of subsystems configuration.


APCS of Transfer Lines

We are ready to provide automated transfer lines for various purposes including:

    • Belt conveyors;
    • Worm conveyors;
    • Scraper conveyors;
    • Elevators, bucket conveyors;
    • Complex conveyor systems using multiple drives;
    • Weighing and dosage devices etc.


APCS of Wastewater Treatment Facilities

Wastewater treatment facilities for both domestic and industrial wastewater, that were in operation in the former Soviet Union, are more or less similar technology and design. Commercial wastewater purification technology includes processes of wastewater inlet, mechanical treatment, biological treatment with activated sludge, advanced treatment, mechanical sludge dewatering and other processes and equipment at pumping stations as well as auxiliary technologies for wastewater treatment facilities to meet their own needs.