KCS- MCS Workshop

Erlangen, February 2007

Industrial Solutions and Services

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 Topics
Optimisation
with CEMAT ƒ Process optimisation - why
KCS - MCS
ƒ Process optimisation - with CEMAT

ƒ Process optimisation - CEMAT examples

- Kiln Control KCS
- Mill Control MCS

ƒ CEMAT optimisation system - Structure

- Hardware
- Software
- Engineering
ƒ Process optimisation with CEMAT
- Commercial aspects
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ƒ Discussion
 Process Optimisation System - why ?

Optimisation
with CEMAT
KCS - MCS Without automatic process control

ƒ the operators have to master all instable and critical situations

ƒ the operators have to adjust the setpoints of all

the interdependant controllers propperly at any time

ƒ diffrent attitudes of personal lead to diffrent production results

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 Process Optimisation System - why ?

Optimisation
with CEMAT With automatic process control
KCS - MCS

ƒ the operators are freed from monotonous routine work

so that they can concentrate on the more specific tasks

ƒ the setpoints of controllers are at any time set to achive

stable production conditions at an optimum level

ƒ the production will be controlled always with the same

characteristic -
setpoint changes will be made
as quickly as necessary
as smoothly as possible
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 KCS and MCS from CEMAT
THE SOLUTION for the Cement Industry

Optimisation
with CEMAT
KCS - MCS

The challenge
process optimisation

Our answer:

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 KCS Kiln Optimisation System

Optimisation
with CEMAT KCS kiln control offers various benefits:
KCS - MCS

ƒ Increase efficiency through a more stable production

ƒ Increase quality through more stable sintering conditions

ƒ Extend lifetime of refractory and equipment

ƒ Increase the operator`s performance by freeing him

from time consuming routine work

ƒ Reduce energy consumption

ƒ Reduce emissions through a process control system,

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 KCS Kiln Control System

Optimisation
with CEMAT
KCS - MCS

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 MCS Mill Control System

Optimisation
with CEMAT
KCS - MCS MCS mill optimisation offers various benefits:

ƒ Increase efficiency through a faster startup of the mill

ƒ Increase quality through automatic separator speed control

ƒ Increase productivity
through an automated
and continuous search for
optimal grinding conditions

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 MCS Mill Optimisation System

Optimisation
with CEMAT M C S Highlights
KCS - MCS

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 KCS - MCS Process Optimisation

Optimisation
with CEMAT
Conclusion :
KCS - MCS
Using the CEMAT optimisation tools means:

ƒ working with a very cost efficient package

ƒ having a system tailored to your demands which is

easy to adjust and easy to extend according to future needs

ƒ using modulare, state of the art, software

ƒ benefiting from the many features comming with SIMATIC PCS7

ƒ to be open to future development

ƒ to be open to Neuronal Networks and Fuzzy Logic

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 KCS - MCS Process Optimisation

Optimisation
with CEMAT
KCS - MCS Example: at ICL-Platin works there are:

ƒ two kilns (with cooler)

ƒ three cement-mills

ƒ one roller-mill

optimized with the CEMAT optimisation logic modules

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 CEMAT KCS, MCS
THE SOLUTION for the Cement Industry

Optimisation
with CEMAT
KCS - MCS

System architecture of
Cemat K/MCS

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 Structure - Hardware

Optimisation
with CEMAT
KCS - MCS
Engineering Station
Server
SIMATIC S7
Operator Station

Standard
Hardware
Maintainance,
Interfacing…

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 Structure - Software

Optimisation
with CEMAT
KCS - MCS ƒ modular software

ƒ each function is implemented as one single object :

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 Structure - Software

Optimisation Excample : Primary Fuel Control at ICL-Platin

with CEMAT
KCS - MCS

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 CEMAT – KCS and MCS
By design : easy engineering - with PCS7

Optimisation ƒ proven CEMAT quality

with CEMAT
KCS - MCS
ƒ part of the CEMAT library from SIEMENS-PCS7

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 KCS and MCS Structure
By design : open - to the future

Optimisation
with CEMAT
KCS - MCS

High level optimisation i.e. with Neuro Fuzzy CEMAT-KCS

Project stage 2

KCS - Autopilot CEMAT-KCS

Project stage 1
Automatic kiln control with all controllers networked

Basic Process Automatisation

CEMAT-CS
(individual controllers)

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 CEMAT - KCS
By design: fast implementation - fast results

Optimisation
with CEMAT % Availability during KCS operation
KCS - MCS 100

90

80 III
II
I
70

60

50

40

30 Siemens
Client
20

10

0
1 2 3 4 5 6 operating months
SW installation On-line operation Possibly changing/amendment
of the software configuration (OFK) fine parameterisation
Off-line test Process monitoring
re- parameterisation
first-up para - re- parameterisation
meterisation (Possibly application ofFuzzy Software Rules )
Training of client's personnel

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 CEMAT Optimisation
THE SOLUTION - for the Cement Industry

Optimisation
with CEMAT
KCS - MCS

KCS - MCS
form Cemat :

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 CEMAT - KCS
THE economic solution

Optimisation
with CEMAT
KCS - MCS

CEMAT-KCS offers a good ROI, because

Planning and implementation can be done in a short time

‹ The system is tailored to your demand
‹ No specific training or tool is required
‹ Optimisation can be done by the plant`s own process people
‹ The system is modular and open to future extensions

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 Discussion

Contact:

Stefan Siegel
Thank you for your attention I&S IS E&C PS 121
Werner von Siemens Str 65
91052 Erlangen
Tel: +49 175 22 16372
Mail: stefan.siegel@siemens.com

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