dr eduardo gallestey effective energy abb switzerland ... will try to give a very brief introduction...
TRANSCRIPT
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Effective Energy Management in the Cement Industry
Dr Eduardo GallesteyABB Switzerland
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CPM Overview
Process Optimization SolutionsPID Loop Performance Monitor
Expert Optimizer for Advanced Process ControlProcess Optimization
Economic Process Optimization
Typical applications in other industries
Knowledge Manager for KPI surveillance
Conclusions
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Knowledge Based Solutions for Cement
Process Control, Laboratory, Manual Data
Raw Data
Information
Dispatch Automation Solutions
ERP
MM/SD PP-PI PM
Lab Solutions
Quality
Robotics
Knowledge Manager
Production Information Management
Production Accounting
SAP Integration
Laboratory Information Management
Economic Process Optimization
Thermal Energy Electrical Energy
Expert Optimizer
Kiln Optimization
Raw Mix Proportioning
Calciner Optimization
Grinding Optimization
Raw DataSetpoints
Plant Schedule
QM
Information
KBS Knowledge Based Solutions
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Process Optimization Scope
Process Control and Sensors
MeasurementsActuator Setpoints
Advanced Process Control
Online Multivariable Control
Soft or Virtual Sensors
Plant StatusPlant Schedule
Economic Process Optimization
Thermal Energy Electrical Energy
Short Term Production Scheduling
Actuators, Measurements
Loop Parameters
Loop Performance Management
Loop Tuning and Diagnostic
Plant Wide Disturbance Analysis
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Plant Surveys Prove the Need
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Loop Performance Manager Benefits
TuningWith LPM Process Engineers (also non expert in control theory) can optimize Loop behaviorBenefits: increase process profit, more stable working condition, more safety operations
AuditingControl Performance Monitoring is non-invasive, simple to perform and very efficientLPM detects automaticallyproblem at the beginning of their occurrencePerformance monitoring nowadays answers the most important questions to help the plant personnel to pinpoint and remove problemsThe right information to the right people
LPM is ABB’s solution for loop analysis and tuning
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Expert Optimizer Scope
Process Control and Sensors
Measurements
Economic Process Optimization
Thermal Energy Electrical Energy
Actuators Setpoints
Plant StatusPlant Schedule
Process Optimization
Kilns, Calciners
Blending
Flotation
Grinding
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Estimation of process state variables
(MHE, Fuzzy Logic, Neural Networks)
Pro
cess
Sen
sors
Act
uato
rs
Computation of optimal set-points
(MPC, Fuzzy Logic)
Preprocessing of measurements
Post-processing of set-points
State estimates
Measurements
Set-points
(800
xA) C
ontro
l Pla
tform
Expert Optimizer – APC Strategy
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Graphical Model Development
drag & drop
HMI
Real-timeCalculation
Engine
Plant model
Libraries/Palette
State update
Control action
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Expert OptimizerThin client based graphical engineering and
programming environment Controls and optimizes your process by using
advanced control techniques and deep process knowledge
TechnologyModel Predictive ControlFuzzy Logic, Neural Networks
Typical BenefitsProcess variability reduced: 20%-50%Energy efficiency increased: 3%-5%Environmental compliance securedQuality requirements fulfilledManage operational complexity!
Installed BaseMore than 150 systems worldwideMore than 300 applications since mid 1990s More than 190 kilns, 90 mills, 40 ore blending
Expert Optimizer Solutions
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How is it done? – “Adaptive” Heat and Mass Balance
Counter CurrentHeat/Mass Exchanger
Energy/Mass Source
Energy/Mass In
Energy/Mass OutEnergy/Mass In
Energy/Mass Out
Energy/MassSink
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Expert Optimizer for Calciners and Kilns
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Results
-60 -40 -20 0 20 40 60 80 1000
2
4
6
8
10
12
Temperature deviation from setpoint [°C]
Frac
tion
of to
tal m
easu
rem
ents
[%]
EO activeEO inactive
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Expert Optimizer Solutions in Cement
Raw Mix PreparationAdjusting additives for raw mix quality
Precalciner ControlFuel and Fan are controller toKeep temperature and O2 levels
Kiln ControlControlling fan, fuel and feed for stable kiln conditions
Mill ControlControlling fresh feed and separator speed to stabilize the mill
Mix Bed BlendingMixing the quarry zones for lower variability
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Expert Optimizer for Ore Concentrators
SAG and Ball Mill ControlControlling speed, feed, water and feed
Goal: stable mill conditions, lower energy consumption, more production
Flotation Circuit ControlControlling levels, air, and chemicals addition
Goal: better recovery at given grade
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Economic Process Optimization Real-Time integration of automation, information, and collaborative business systems across the enterprise.
Closing the gapbetween financial goals and the
process. In real time!
Economic Process Optimization thanks enterprise systems integration
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Electrical Energy Management
GoalsHigh production at lowest possible energy bill Contractual and equipment constraints Scheduling of big consumers
Problem CharacteristicsHigh power consumptionReaction to deviations from original plan Variable/complex electricity contractsDifferent consumers, different characteristicsNumerous productsSilos and conveyor belt system
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Electrical Energy Management ModulePower cost down by 2-3%Automatic rescheduling in case of unexpected eventsStrict contractual and equipment constraint satisfaction
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Applications done by ABB: Water SupplyWater Supply
Generation of schedules High pressure pumpsDelivery of ground water Purchase of ground water
DataWater demandReservoir levelsTransport timesEnergy prices
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Applications done by ABB: Steam SupplyIndustrial Steam Supply
ApplicationsAlumina plantsPulp and Paper PlantSteel
Control of boiler pressure SP Valves SPBuy and sell decisions
DataSteam demand (variable!)Node pressuresBoiler efficienciesEnergy prices
APC OFF APC ON
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Applications done by ABB: Pulp and PaperCustomer - Tiger Mill Fiber Line
Maximizing throughput at the right quality with the lowest cost
Result: on-line production planningManipulated variable optimization
Production prediction for 3 days
Problem sizeNumber of process units: 7
Number of buffers: 8
Fiberline model: 422 Variables
Number of EO manipulated variable: 16
Number of EO controlled variables: 8
TechnologyNonlinear Model Predictive Control
Modelica Models
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Knowledge Manager: Tracks Energy Consumption
Thermal Energy KPIsSpecific energy consumption per productThe rate of substitution of traditional fuels with alternative fuelsUnderstanding the economic impact of different fuel mixes
Electrical Energy KPIsSpecific energy consumption, material preparation, productsThe specific energy consumption per equipment and productUnderstand the impact of plant scheduling
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Effective Energy Management
Electrical Energy Savings by variable speed drive solutions Thermal Energy Savings by blending and kiln control systemsElectrical Energy Savings by grinding control systems
Thermal Energy Cost Savings by fuel mix optimizationElectrical Energy Cost Savings by mill schedule optimizationEnergy KPI Supervision with Knowledge Manager
Reduce your energy consumptionReduce your production costs
Gain environmental sustainability
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OutlookAPC portfolio selected Winner of the Global Fuels Conference Award for “most innovative technology for electrical energy savings”
Selected by conference participants
Proof of customer value
Check for new solutions in conjunction with SOLBAS technology