Processexpert Kiln

7/28/2019 Processexpert Kiln

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ECS /ProcessExpert- KilnPP-7004.PXP.0001

an application that brings together decades o automation experienceto design and optimise a control solution orYOUR kiln.


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ECS /ProcessExpert - Kiln

IntroductionControlling a cement kiln has always been a challenging task or

cement plant operators. These days, a computer-based pyro con-trol system is not merely nice to have, it is a practical necessity.Both the inherent complexity o the pyro process and the

ar-reaching consequences o o-spec clinker, aulty operatingconditions and production shutdowns make an automated

control system indispensable.

For 30 years FLSmidth Automation has been a pioneer in high-level expert control systems or cement kiln applications.

ECS/ProcessExpert-Kiln is based on the latest developments with-in proven technologies, such as Fuzzy Logic, Model-based Predic-tive Control and Statistical Process Control. The applications

ocus on meeting control challenges o pyro processes throughbest applied technologies. Today, the control strategies behindECS/ProcessExpert-Kiln are based on two decades o experience

in cement kiln control and optimisation projects

Application Benefts150+ installations world-wide on pyro processes o various na-

ture, type, and manuacture, have typically produced the ollow-ing results:

Controller StructureThe generic structure o an ECS/ProcessExpert-based controlstrategy is shown schematically in Figure 2. Using the systemsprocess I/O drivers, raw process measurements are introduced

into the controller. There are 30-40 digital and analog input sig-nals or a typical kiln controller. The relevant signals are validatedand pretreated beore being used in the control strategy so that

the conditions o the measuring devices are taken into account.To acilitate structuring o the controller, a number o so-calledkey perormance indexes are calculated.

3-8%higherproduction

2-4%lowerfuelconsumption. upto30%lowerstandarddeviationoffreelime

paybackofinvestmentinlessthanayear

Muchfewerproblemswithcycloneblockageandkilnring

ormation ConsistentqualityMorestableoperation

The operators general impression o ECS/ProcessExpert-Kiln is:

Burning Zone Temperature Index, Kiln Operation Stability Indexand Kiln Heat Consumption Index are examples o these indexes.The key perormance indexes then represent the process condi-

tions in the subsequent decision-making procedure. In this pro-cedure, the size o actions, which are typically changes in the setpoints, and the right timing o the actions are determined. The

timing o the actions depends very much on the process dynam-ics. The actions decided upon are subsequently transormed intoa set o easible set points in the process.

Figure 1: Control-relevant inormation rom a pyro system may consist o more than 40 process measurements and actuators.

A human operator is not able to handle all this inormation every fve seconds. But the operators decision-making know-how

or a given process is essential. ECS/ProcessExpert orms an environment in which the operators process knowledge is integrated

into a computer-based advanced control strategy.


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General Description

Dealing with complexityEach kiln has its own characteristics, limitations, operational chal-

lenges and control requirements. So the control system to dealwith this complexity must be implemented in an environmentthat enables breaking down the complexity.

For this reason, ECS/ProcessExpert has a hierarchical structure orthe decomposition o a complex control strategy. In the case o a

kiln control system, the decision-making block shown in fgure2a typically consists o three control groups that are related toa specifc part o the process (fgure 2b).

Each control group is an assembly o control objectives (fgures2c/2d) that are specially designed to handle upset conditions, orexample ring all or high CO in the kiln inlet, or to reach certain

operation targets, or example ree lime control.

Similar to manual control in which upset conditions receive max-imum attention, ECS/ProcessExperts so-called priority manag-

er organises the objectives in a control group. For example, ithe CO measurement in the preheater is high, drastic action on

the ID an is needed. The priority manager then suppresses lowerpriority objectives such as kiln O2 control to remedy the situationin the preheater.

The purpose o the control objective, Process Limitations, shownin fgure 2c, is to handle the physical limitations o operatingunder normal conditions. For example, i the ID an is running at

ull speed and the Kiln Drat Index is still low, the controller willlower the throughput to avoid operational difculties such as ringormations and o-spec product quality.

Figure 2: The controller design in ECS/Process Expert has a hierarchical structure that breaks down complexity.

Figure 3: When burning alternative uels, the add-on Mul-

tiuel module ensures the best possible mix o the uels

available. The module is designed to deliver a consistent

heat value at the lowest possible cost. The controller usesa predictive technique to handle uel eeder constraints

and dynamics. This is done to plan and automatically ad-

just the eeder set points with a view to minimising com-

bustion disturbances in the kiln. Mulfuel can work as a

stand-alone application with third-party automatic kiln

controllers as well as manual operator control.


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www.fsautomation.com

FLSmidth A/S Automation. All rights reserved.

ECS/ProcessExpert, ECS/CEMulator, ECS/PlantGuide, QCX/RoboLab, QCX/OnStream, ECS/CemScanner,

ECS/ACESYS, ECS/ControlCenter, ACE/Woodware, ECS/SmartStation, ECS/StackGuide, QCX/Laboratory,

QCX/AutoSampling, QCX/AutoPrep, QCX/BlendExpert, QCX/BlendMaster and Kilnloq are either registered

trademarks or trademarks o FLSmidth A/S Automation in the United States and /or other countries. All other

trademarks are property o their respective owners.

FLSmidth Automation reserves the right to change specifcations without prior notice. Our brochure makes no

oers, representations or warranties (express or implied), and inormation and data contained in this brochure

are or general reerence only and may change at any time. Please contact us or specifc inormation or data that

may relate to your interests.

ECS /ProcessExpert- Kiln

Application Features

Measurement validation.

Key Perormance Index generation.

Process customized abnormal situation management

Process customized operation objective

Priority Management o the objectives.

Kiln stabilization and uel optimisation.Integrated or stand-alone Multiuel module.

Calciner operation control.

Clinker quality control.

Sotware Features

Graphical decomposition in control strategy design.

Predefned building blocks or ast confguration

purpose.

Confgurable operator interace.

Advanced trend and perormance reporting.

OPC interace support or integration with SCADAsystems rom the major suppliers.

Communication capabilities to PLC systems rom the

major suppliers.

Figure 4: The operator interace to ECS/ProcessExpert is a user-riendly environment that contains the relevant inormation on kiln

operating conditions and control perormance. The user interace is based on proven ECS technology providing powerul acilities

or alarm handling, trends and reporting, object statistics, etc.

Customisation solutionThe number and type o control objectives depend on the

operational issues o a given project. To customise the controlstrategy, it is essential to hold intensive interviews and make proc-ess studies with the technical sta o the production line.

ECS/ProcessExperts open implementation environment, whicheatures a strong object-oriented and hierarchical methodology,has proved successul in solving many special process problems.

Both the engineering and commissioning o a controller are con-sidered a joint project between the customer and

FLS Automation. In this way, a successul end result is ensured tothe beneft o both parties, with solution know-how and mainte-nance knowledge being efciently transerred to the end user.

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Processexpert Kiln