Wonderware Software Brings Aggregate Plant Up-to-date and Enhances Operations

Independence, Ohio — Just a couple of years ago, a time traveler from the 1800s visiting the DiGeronimo Aggregates plant would have been in familiar surroundings. The operation was burning gas and oil and operating as it had for the last 150 years — crushing raw shale and bringing it to the kiln where it is heated, then cooled, ground and graded. The process yields a versatile end product that is used for high-performance, lightweight structural concrete and masonry, professional turf, horticultural applications and geotechnical fills.

But the plant's new owners had a more modern vision and aspirations to improve productivity and product quality while planning for future expansion. They set about transitioning the facility to coal fuel, upgrading the electrical system and other equipment to better meet EPA regulatory requirements, and improving the overall effi ciency of the enterprise.

Managing a Multifaceted Project

The management team at DiGeronimo Aggregates wanted to implement the new system in the most cost-effective and timely manner, so they decided to supervise the project internally, enlisting a number of key partners to assist. Wonderware Cincinnati, the regional Wonderware distributor working closely with the management team recommended Hull & Associates, Inc. a Wonderware ArchestrA® Certified System Integrator with experience in electrical engineering and control systems automation. DiGeronimo agreed with the selection of Hull & Associates, Inc. because they could provide standardization through the Wonderware software solution that would enable coordination of the many suppliers, which was vital to the teamwork and ultimate success of the complex implementation.

Besides the economic advantages of switching from oil to coal, the initial analysis uncovered an opportunity to design and deploy a centralized manufacturing automation solution incorporating programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) capabilities, and a human machine interface (HMI). The resulting system was projected to decrease energy use and deliver operational cost savings as well as a higher quality, more consistent product.

Challenges for Operators and Management

Because of the age of the plant and its 65-acre size, operators faced a number of impediments. Their primary means of monitoring the kiln was visual; if the size of the fl ame seemed steady, the temperature should be in an acceptable range. More accurate, real-time data was not available and conduit running between the numerous stations was used for wired communications. Operators had to travel to remote stations to determine whether they were functioning properly and to record and report data.

Additionally, the plant management offi ce was across town, so executives did not have the ready access to current performance data that they needed for informed decision making.

The Kiln is the Key Component

The centerpiece of DiGeronimo Aggregates is the kiln, which heats the crushed shale, altering its cellular structure to form a material which is light, yet extremely strong and durable. To produce consistent product batch after batch, the kiln temperature must remain as stable as possible at around 2,200 degrees Fahrenheit.

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