Bringing a major industrial facility back online after more than a decade of dormancy requires unparalleled engineering precision. The Libyan Cement Company (LCC) production line had been completely offline since 2010, heavily restricted by an obsolete and unsupported KHD Distributed Control System.
Our engineering leadership was tasked with a complete architectural resurrection. We executed a full reverse-engineering of the legacy KHD logic, migrating the core process areas—spanning the Raw Mill, Kiln, and Cooler—to a highly deterministic Siemens SIMATIC PCS 7 architecture.
Rapid Reverse-Engineering & Resurrection
The timeline for this reactivation was incredibly aggressive. Relying on deep domain expertise in cement process control, our team completed the total reverse-engineering, logic conversion, and new programming for the entire facility within a staggering two-month window.
- Complete Legacy Migration: Successfully reverse-engineered decades-old KHD DCS logic without relying on modern documentation, ensuring zero loss of operational philosophy.
- CEMAT Library Standardization: Deployed the industry-standard Siemens CEMAT Minerals library to optimize motor control, safety interlocks, and alarm management across the Raw Mill and Kiln areas.
- High-Availability Architecture: Integrated AS 410-5H redundant controllers combined with ET 200M distributed I/O to guarantee uninterrupted, continuous heavy material production.
- Accelerated Delivery: Completed the Factory Acceptance Testing (FAT) immediately following the two-month programming phase, validating all 7,000 I/O loops against simulated real-world conditions.
- Flawless Startup: Transitioned from a dormant, decade-old baseline to a seamless, modernized commissioning phase, officially restoring critical production capacity to the Libyan industrial sector.
