ECS/ProcessExpert- Kiln

 an application that brings together decades of automation experience to design and optimise a control solution for YOUR kiln.

ECS /ProcessExpert- Kiln

PP-7004.PXP.0001

ECS /ProcessExpert - Kiln

Introduction
Controlling a cement kiln has always been a challenging task for cement plant operators. These days, a computer-based pyro control system is not merely nice to have, it is a practical necessity. Both the inherent complexity of the pyro process and the far-reaching consequences of off-spec clinker, faulty operating conditions and production shutdowns make an automated control system indispensable. For 30 years FLSmidth Automation has been a pioneer in highlevel expert control systems for cement kiln applications. ECS/ProcessExpert-Kiln is based on the latest developments within proven technologies, such as Fuzzy Logic, Model-based Predictive Control and Statistical Process Control. The applications focus on meeting control challenges of pyro processes through best applied technologies. Today, the control strategies behind ECS/ProcessExpert-Kiln are based on two decades of experience in cement kiln control and optimisation projects

Application Benefits
150+ installations world-wide on pyro processes of various nature, type, and manufacture, have typically produced the following results: 3-8 % higher production 2-4 % lower fuel consumption. up to 30% lower standard deviation of free lime payback of investment in less than a year The operators general impression of ECS/ProcessExpert-Kiln is:  Much fewer problems with cyclone blockage and kiln ring formation Consistent quality More stable operation

Figure 1: Control-relevant information from a pyro system may consist of more than 40 process measurements and actuators. A human operator is not able to handle all this information every five seconds. But the operators decision-making know-how for a given process is essential. ECS/ProcessExpert forms an environment in which the operators process knowledge is integrated into a computer-based advanced control strategy.

Controller Structure
The generic structure of an ECS/ProcessExpert-based control strategy is shown schematically in Figure 2. Using the systems process I/O drivers, raw process measurements are introduced into the controller. There are 30-40 digital and analog input signals for a typical kiln controller. The relevant signals are validated and pretreated before being used in the control strategy so that the conditions of the measuring devices are taken into account. To facilitate structuring of the controller, a number of so-called key performance indexes are calculated. Burning Zone Temperature Index, Kiln Operation Stability Index and Kiln Heat Consumption Index are examples of these indexes. The key performance indexes then represent the process conditions in the subsequent decision-making procedure. In this procedure, the size of actions, which are typically changes in the set points, and the right timing of the actions are determined. The timing of the actions depends very much on the process dynamics. The actions decided upon are subsequently transformed into a set of feasible set points in the process.

General Description

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

Dealing with complexity

Each kiln has its own characteristics, limitations, operational challenges and control requirements. So the control system to deal with this complexity must be implemented in an environment that enables breaking down the complexity. For this reason, ECS/ProcessExpert has a hierarchical structure for the decomposition of a complex control strategy. In the case of a kiln control system, the decision-making block shown in figure 2a typically consists of three control groups that are related to a specific part of the process (figure 2b). Each control group is an assembly of control objectives (figures 2c/2d) that are specially designed to handle upset conditions, for example ring fall or high CO in the kiln inlet, or to reach certain operation targets, for example free lime control. Similar to manual control in which upset conditions receive maximum attention, ECS/ProcessExperts so-called priority manager organises the objectives in a control group. For example, if the CO measurement in the preheater is high, drastic action on the ID fan is needed. The priority manager then suppresses lower priority objectives such as kiln O2 control to remedy the situation in the preheater. The purpose of the control objective, Process Limitations, shown in figure 2c, is to handle the physical limitations of operating under normal conditions. For example, if the ID fan is running at full speed and the Kiln Draft Index is still low, the controller will lower the throughput to avoid operational difficulties such as ring formations and off-spec product quality.

Figure 3: When burning alternative fuels, the add-on Multifuel module ensures the best possible mix of the fuels available. The module is designed to deliver a consistent heat value at the lowest possible cost. The controller uses a predictive technique to handle fuel feeder constraints and dynamics. This is done to plan and automatically adjust the feeder set points with a view to minimising combustion disturbances in the kiln. Mulfifuel can work as a stand-alone application with third-party automatic kiln controllers as well as manual operator control.

ECS /ProcessExpert- Kiln

Figure 4: The operator interface to ECS/ProcessExpert is a user-friendly environment that contains the relevant information on kiln operating conditions and control performance. The user interface is based on proven ECS technology providing powerful facilities for alarm handling, trends and reporting, object statistics, etc.

Customisation solution
The number and type of control objectives depend on the operational issues of a given project. To customise the control strategy, it is essential to hold intensive interviews and make process studies with the technical staff of the production line. ECS/ProcessExperts open implementation environment, which features a strong object-oriented and hierarchical methodology, has proved successful in solving many special process problems. Both the engineering and commissioning of a controller are considered a joint project between the customer and FLS Automation. In this way, a successful end result is ensured to the benefit of both parties, with solution know-how and maintenance knowledge being efficiently transferred to the end user.

Application Features Measurement validation. Key Performance Index generation. Process customized abnormal situation management Process customized operation objective Priority Management of the objectives. Kiln stabilization and fuel optimisation. Integrated or stand-alone Multifuel module. Calciner operation control. Clinker quality control. Software Features Graphical decomposition in control strategy design. Predefined building blocks for fast configuration  purpose. Configurable operator interface. Advanced trend and performance reporting. OPC interface support for integration with SCADA  systems from the major suppliers. Communication capabilities to PLC systems from the  major suppliers.

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 of FLSmidth A/S Automation in the United States and /or other countries. All other trademarks are property of their respective owners. FLSmidth Automation reserves the right to change specifications without prior notice. Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. Please contact us for specific information or data that may relate to your interests.

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