Industrial : Optimization For The Cement Industry

IndustrialIT: Optimization for theCement IndustryOptimizeIT Expert Optimizercourier

OptimizeIT Expert OptimizerOPTIMIZED PROCESSApplication ive fuelsMillsTrainingProduct SupportExpert OptimizerExpert OptimizerTechnologyThe cementindustry facesincreasingpressure formore stringentrequirements onprofitability,product quality,legislationon emissioncontrol and anincreasinglycompetitivemarket situation.OptimizeIT ExpertOptimizer – anexpert controlsystem – will helpyou reach thesegoals.What is Expert OptimizerWhy Expert OptimizerOptimizeIT Expert Optimizer is a hybrid intelli-It’s primary objective is to achieve continuousprocess optimization and thereby improve theplant’s overall performance. Hence its advantageas a graphical engineering and programmingenvironment, used to control and optimizegent-system product developed by ABB. Partof its wide optimization suite, it is primarilydesigned for expert closed-loop process controland optimization of industrial processes, but canalso be used for decision-support applications.Hybrid intelligent system are not a substitute forplant DCS or PLC systems. Rather, they are a highlevel supervisor for supplying setpoints to thelower layer of control systems. Our hybrid intelligent system, the OptimizeIT Expert Optimizerposseses human-like knowledge within specificdomain. Adapting itself and learning in changingenvironments, it makes decisions and takesactions.with a combination of proven and advancedcontrol techniques. OptimizeIT Expert Optimizeradds value to the operational performance bybringing the process closer to its operationallimits.In coordinating the setpoints of the differentparts of the process, and immediately detectingdeviations among the different parts of the mineoperation, OptimizeIT Expert Optimizer is a keytool for all – plant performance, it helps plantmanagement reach enterprise profitability andsustainability goals.Tangible Benefits Increased profits (5%–10%) Increased production (3%–10%) Energy savings (3%–7%) More stable product quality (10%–20%)2 Kilns Mills Alternative fuels

Maximum Process CapacityPROCESS THROUGHPUTOptimized SetpointOptimizeBenefitsdue toOptimizationManual SetpointStabilizeManualAutomatic using Expert OptimizerTIMEDiagram showing Expert Optimizer drawing the process setpoints.to the maximum process capacity.How does OptimizeIT Expert Optimizer workComplex real-world problems require intelligentsystems that form partnerships with differentcontrol design methods. Thus, the OptimizeITExpert Optimizer provides a comprehensive varietyof advanced control techniques for appropriatestrategy development. Coupled with the graphicalengineering environment, this ensures fast development and implementation with low cost systemmaintenance.neural networks, and model-based control. OptimizeIT Expert Optimizer has successfully appliedthis technique and achieves more than 2 millionhours, run-time in closed loop control every year.As today, Expert Optimizer is controlling morethan 260 processes worldwide. It is saving morethan 100 million to our customers, year after year.Combinationof provenadvancedcontrol techniques anddeep processknowledgeguaranteesthe systemsuccess.Process behavior is often well-known to experts.The expert knows and understands the forcesacting on the process. This allows him to build adetailed relationship, able to link process outputand inputs. For thisreason, our core control strategy consists of multi-variable fuzzy ruleblocks,OptimizeIT Expert Optimizerprovides: unmatched performance Tirelessly supervises desiredprocess parameters Unchallenged reaction speed Consistently takes the best decision Executes many small changes asopposed to few large changes Immediately recognizesabnormal conditions and actsaccordingly3

Cement Kiln OptimizationMeet your quality targets by maxinizing your kiln troughput – How? By using Expert OptimizerExpert Optimizeroptimizes thecement kilnprocess.To achieve thishowever, itsstabilization mustoccur beforemanipulatedvariables aredriven to itsconstaints.Controlling a cement rotary kiln is a verydifficult task. The process is intrinsically unstableand there are long time delays and large perturbations acting on it. Only a perfect mix of experience, deep knowledge, mathematical techniques and state-of-the-art software can achieveoptimal behaviour over long periods of time.Expert Optimizer is a system tailored for theseneeds.The potential benefits a user can expect toachieve by installing Expert Optimizer can beassessed on the basis that performance willimprove from that of an average operator to thatof a best operator performing at its optimum for24 hours a day, every day.BENEFITSSPECIFICATIONSQuantifiable process benefits4OptimizeIT Expert Optimizer controls a kiln by: Checking for abnormal conditions, prioritizing their importance and taking specialactions to bring the process back to normal. Using various of control techniques tomaintain process stability. Once the process is stabilized, make numerous small changes to drive the process closerand closer to the process constraints.Increased output (3%–10%)Lower fuel consumption (3%–7%)Longer refractory life (10%–15%)Better and more consistent quality (10%–20%)

Input dataMeasure and monitorprocess conditionsStabilise processwith small frequentset-point changesDetect processcondition changesMove stabilisedprocess to the optimumProduct qualityEnergy efficiencyMaximum outputThe Reaction Sequence in Clinkerization C Preheating1400 –1200 –1000 –800 –600 –200 –0Residence time:10 secGas1 minMaterialRaw mixCalciningBurning & ClinkeringCoolingMaterial60 m3–5 sec1 sec30 min10 sec30 minExit gas340 CPrecalcinerCoal feedAir ductCoal feedO2CONOXKiln d 5m40 t Co2 Dust 10kg(after E.P.)100t Raw mix(CaCO3)The presence of both exothermic and endothermic chemical reactions makes the cement kilnprocess unstable. This means that achieving anideal temperature profile through the kiln isessential to meet expectations on process stabilityBENEFITSSPECIFICATIONSBenefits Grate coolerClinker60t Clinker(CaO compounds)and performance. Expert Optimizer can solve thisproblem. It has been applied to the cement kilnprocess more than 170 times in 15 years, achieving an impressive record of performance and savings and creating value to for our customers.Expert Optimizerhas been appliedto the cementkiln processmore than 170times, creatingvalue for ourcustomers.Control strategy focused on business objectivesLower plant maintenance costs through improved run timesControl of plant emissions to meet environmental legislationConsistent control of the process,eliminating shift-to-shift variations Enhancement of kiln-specific knowledge5

Alternative Fuels Optimization“Use OptimizeIT Expert Optimizer to burn alternative fuels and increase profitability.”Cement industrykilns areincreasinglyburning wastefuels to capitalizeon the costbenefits offeredby alternativefuels andhazardousmaterials.Burning alternative fuels can lead to instabilityin the clinker manufacturing process.Expert Optimizer controls the mixing of alternative fuels to ensure consistent burning, whilemaking sure the kiln does not become unstablethrough changes in calorific values of the fuels.Normally Expert Optimizer is designed to allowthe kiln to use the minimum amount of thermalenergy. But if the cement manufactures goal is todispose of the alternative fuels, then the ExpertOptimizer strategy can automatically be adjustedto maximize the burning of such fuels thus savingthe customer money. Expert Optimizer has theability to control the combustion of different fuelssimultaneously.Users must however meet stringent monitoringand control policies established by environmentalagencies before burning any alternative fuels.The Expert Optimizer Alternative Fuels ControlModule is approved by environmentalagencies in North America and Europe.The system ensures that best practices are usedat all times, while avoiding shift-to-shift variationsand reducing operating costs without destabilizingthe process.BENEFITSSPECIFICATIONSBenefits Increased usage of alternative fuels (5%–20%) More stable product quality (10%–20%) Reduced fuel costs (5%–20%) Lower maintenance costs and fewer pollution emissions (5%–20%)6

Emission Optimization“Use OptimizeIT Expert Optimizer to limit the impact on the environment.”OptimizeIT Expert Optimizer reduces cementmanufacturers’ emissions in three distinct areas: The burning of cement clinker in rotary kilnsis controlled more efficiently, thus reducingthe energy requirements of the process. Thisreduction in the energy consumption reducesthe quantity of alternative exhausts emittedinto the atmosphere. Cement industry kilns are increasinglyburning alternative fuels to capitalize on thecost benefits offered by alternative fuels andhazardous materials. Moreover, the CO2 emissions produced by these fuels do not influence the enterprise environmental balance.Expert Optimizer helps to achieve the processstability needed to maximize the usage ofthese fuels.The kilnoptimizationstrategy focuseson reducing NOxemissions whilestill maintainingthe correct levelof thermal energy. The kiln process runs at much lowertemperature, which reduces the amount ofNOx formed in the flame. The effectivenessof Expert Optimizer as a tool to reduce NOxemissions has been recognized in the form ofan environmental award presented to ABB bythe British government.BENEFITSSPECIFICATIONSBenefits Efficient control reduces energy requirements Lower burning temperature reduces amount of NOx formed inthe flame Expert Optimizer is recognized by environmental authorities asthe best available technology for the burning of alternative fuels.7

Grinding Optimization“Use Expert Optimizer to improve profit via larger throughput and lower powerconsumption”Expert Optimizerhas beensuccessfullyappliedin more than90 mills, tooptimize millingoperations.OptimizeIT Expert Optimizer benefits thecement mill operations in four ways: More consistent quality (grade).The continual monitoring of the mill loadingand the adjustment of the feed and separatorresults in reduced variations in cement grade.This has the added benefit of a more consistentproduct quality. The control strategy isdesigned to respond to disturbances in theprocess but still achieve quality consistency. Increased output.By continually monitoring both the loading ofthe mill and the balance of material flowsthrough the system, it is possible to identifysituations when the feed to the mill and theoutput can be increased. Increased outputover extended periods of time has beenobserved on mills controlled by ExpertOptimizer. Reduced power consumption.This important saving is a result of the softerclinker produced by a kiln controlled byExpert Optimizer. The control strategy isable to make optimum use of the availablemill capacity and improve the production rate. Reduced consumption of grinding media.As a result of the softer clinker produced inkilns controlled by Expert Optimizer theconsumption of grinding media is reduced.The main benefits of Expert Optimizer Controllingthe grinding circuit of a raw mill are an increasein output and a reduction in power consumption.BENEFITSSPECIFICATIONSCement mills Production increase (3%–10%) Power saving, (3%–7%)Raw mills Production increase (3%–10%) Power saving (3%–7%)8