8_9_Mill Optimisation Part 1 and 2

November 2009QCX/OLX900 1March 2010www.flsmidth.com/automation

November 2009QCX/OLX900 2

Agenda

Automation Group. Solutions -QCX (Part 1) Solutions -ECS. (Part 2)

November 2009QCX/OLX900 3June 2008www.flsautomation.com

FLSmidth Automation Group

FLSmidth Automation is a division of FLSmidth We have more than 30 years of experience in total plant automation

and quality control systems FLSmidth Automation’s first software solution was commissioned in

1971 More than 700 control systems (ACE, AME and ECS solution suite)

supplied world wide We have supplied more than 450 laboratory/quality automation

systems (QCX solution suite) worldwide.

FLSmidth Automation aim at being our customers' preferred partner,offering ONE SOURCE solutions and products that

strengthen our customers’ competitiveness- we are today a leader in our fields of automation -

FLSmidth Automation Group

Technology Subsidiaries

Partners

November 2009QCX/OLX900 5February 2010www.flsautomation.com

Business Segments

Source: Net Contribution Calendar Year 2009

Bringing Value to You by Bringing Value to You by Experience and KnowExperience and Know--How!How!

Cement - d irect44%

Cement - indirect19%

Minerals - d irect3%Minerals - ind irect

Other industries13%

Other industries -ind irect

Af termarket21%

Solutions for every operational level

Business Management

Business-critical management information systems

Control

Automation systems that run all plant processes

Sensors & Actuators

Process-enhancing components that provide real-time data

Optimisation

Process-optimising high-level control solutions

Supervision

Applications for monitoring and controlling systems

FLSmidth Automation Solution Pyramid

Control systems, 25%

Lab Automation, 22%

High control level, 16%

Instrumentation & Gas, 19%

Parts & Services, 18%

February 2010www.flsautomation.com

Product Segments

Process and Quality Control Solutions

Securing Our World Leadership Position Securing Our World Leadership Position through Innovation!through Innovation!

Enterprise focus

Managerial focus

Supervisory focus

Operational focus

Machinery focus

ACE:Adaptable

ControlEquipment

QCX:Quality control by

Computer andX-ray

PCI:Power &Control

Integration

ECS:ExpertControl &Supervision

AME:AdvancedMeasuringEquipment

Process Optimization - Why?

To Reduce your Cost. (As simple as that!!) Costs mainly in a cement plant

– EnergyCost in Power consumedCost of CO2 CreditsCost of Fuel -Thermal Energy

– ProductionCost due to high variability of raw materials in the quarry, and

stock pileAdditives at the mill.Cost due to long transition times between productsCost due to high clinker content in final cement production.

How can we help you.?

ECS- Process Control Solutions

QCXQCX -- QualityQuality ControlControl SolutionsSolutions

QCXQCX

QCX is a state-of-the-artlaboratory automation concept

- targeted for the 24/7round the clock QC & QAactivities on a cement plant

only a few other suppliersoffer an equivalent amount of functionality in an integrated system concept. There are many suppliers offering specific ’part’solutions

.. central lab .. central lab automation automation concept ...concept ...

QCXQCX is ...is ...collection & collection & administrationadministrationof analysis data of analysis data and and quality controlquality control

XRFQCX/OnStream

PSZ (laser particle sizing)BlaineC/H (Carbon-Moisture)C/S (Carbon-Sulphur)LOI (Loss on Ignition)XRF (QCX/OnStream)

QCXQCX is also ...is also ...OnOn--line/Inline/In--line/Atline/At--linelineAnalysis Analysis

Raw mealSilo Cement

Clinkerstorage

Cementmill

Raw mill

´Stockpiles

Feeders Feeders

QCX modularityQCX modularity

QCX/AutoSampling

QCX/AutoPrep

QCX/Laboratory (LIMS)

QCX/BlendExpert (QCX/BlendMaster)

QCX/RoboLab

Data exportQCX/OnLine

Analysis

QCX/AutoPrep

QCX/Laboratory (LIMS)

QCX/BlendExpertalso supporting on-line analysis

QCX/RoboLab

QCX/OnLineAnalysis

QCX/QCX/BlendExpertBlendExpertfor raw mix & cement mill quality control + stock pile control & supervision based on :- lab XRF analysis- on-line EDXRF analysis- on-line PGNAA

or any combination hereof+ mix design simulation+ quarry logistics optimization

QCX/LaboratoryQCX/Laboratory- kernel module for sample administration

& tracking, reporting, data import/export- data acquisition and instrument control- unique combination of LIMS and LAS

in a process control environment(LIMS: Laboratory Information Management System)(LAS: Laboratory Automation System)

QCX/QCX/AutoSamplingAutoSamplingfor automatic sampling, in-processsample prep and sample transport

QCX/AutoPrepQCX/AutoPrepfor automatic sample preparation basedon integrated automatic equipment

QCX/RoboLabQCX/RoboLabfor automatic sample preparationbased on robotics technology

QCX QCX - central laboratory

automation and/or- on-line analysis

applications

QCX/QCX/OnLineAnalysisOnLineAnalysisfor ‘on-line’ quality control based on EDXRF analysis (=QCX/OnStream) orPGNAA or particle sizing or .....

QCX/AutoSampling

• open environment

• Windows 2000/2003/2007/XP/Vista/’7’

• state-of-the-art connectivity:ActiveX, ODBC, OLE….

• Microsoft SQL2005/SQL2008

• Microsoft Visual Studio 6/7

• .NET for newest applications

• True Client-Server architecture

• open environment

• Windows 2000/2003/2007/XP/Vista/’7’

• state-of-the-art connectivity:ActiveX, ODBC, OLE….

• Microsoft SQL2005/SQL2008

• Microsoft Visual Studio 6/7

• .NET for newest applications

• True Client-Server architecture

Mix optimizationalgorithms and utilities

On-lineProductionAccounting

Analysisdata

process

on-line QC applications

BlendExpert-Mill

BlendExpert-AQL

Blast & equipment

on-line tracking & mappingmanual consequential calculations(add-on module for QCX/BlendExpert-Pile)

quarry

BlendDesigner

Datacapture

off-line design and static simulation

QC/QA management

QCX mix control modularityQCX mix control modularity

BlendExpert-PileLo

Mix optimizationalgorithms and utilities

Analysisdata

process

on-line QC applications

BlendExpert-Mill

BlendExpert-PileBlendMaster-Mill

BlendMaster-Pile

BlendMaster is a leanerversion of BlendExpert;

targeted for PGNAA based mix control and with some

reduction in functionality

QCX mix control modularityQCX mix control modularity

BlendExpert-Pile

BlendExpert-MillBlendExpert-AQL

BlendDesigner

4 strong applications

BlendMaster-Pile

BlendMaster-Mill

QCX/BlendExpert Product summary

State of the art material proportioning State of the art material proportioning Model Based Predictive ControlModel Based Predictive Control Raw mix or stockpile controlRaw mix or stockpile control Also supporting onAlso supporting on--line PGNAA & online PGNAA & on--line XRFline XRF Flexibility & ModularityFlexibility & Modularity Unique software smartness for both operator and specialistUnique software smartness for both operator and specialist Powerful static simulation for mix designPowerful static simulation for mix design

QCX/BlendExpert-MillQCX/BlendExpert-Pile

Mix optimization

Analysisdata

QCX/BlendDesigner

Data capture

QCX/BlendExpert-AQL

Blast & equipment

+500 sold applications!

InIn--line particle sizing line particle sizing ––sampling & integrationsampling & integration

Control box of Item 1On-site welding on of these standard dimension accessflanges/connection pipeswith the proper inclination andorientation.

No need for cellular wheel sluicewhen return to same chute withminimum height difference betweensampling and return points

Scope borderline FLSmidthCustomer

Test assembly (of previous version)and with Malvern Insitec

Local control cabinet incl laser eqp supplier’s control components

0-360o

Flanges for adjusting

FLSmidth ‘V3’ Sampling & sample handling for in-line

Laser Particle Analyser

FLSmidth FLSmidth ‘‘V3V3’’ SamplingSampling & & sample handling forsample handling for inin--line line

Laser Particle AnalyserLaser Particle Analyser

Optional cellular wheel sluice

Scope borderline

Chute section( not included in scope )

minimum installation height requirement very high flexibility for return of analysed

material very high flexibility for return og by-pass

excess material

minimum installation height requirementminimum installation height requirement very high flexibility for return of analysedvery high flexibility for return of analysed

materialmaterial very high flexibility for return very high flexibility for return ogog byby--passpass

excess materialexcess material

Choice of Malvern ‘Insitec’ or Sympatec ‘Mytos’Laser particle sizer

Choice of Choice of Malvern Malvern ‘‘InsitecInsitec’’ oror Sympatec Sympatec ‘‘MytosMytos’’Laser particle Laser particle sizersizer

OLX900 AnalyzerOLX900 Analyzera QCX/a QCX/OnStreamOnStream productproduct

Platform

Process flow

Optimal quality control

High frequency

Applications forraw mix or cement

Fast control response

Reduced kiln feed variations

Reduced work load

Robust installation

QCX/OnStream combines sampling, analysis and process control

Well proven technology

Old OSCA 3000

versionOld OLX800

version

OLX900 is the 5th generation of analyzers incorporated into theQCX/OnStream product range, since 1st analyzer version in 1993

Ruggedized cabinet (IP54)

Analyses 4 main elements:Fe, Ca, Al, Si(options for S & Mg)

Energy dispersiveX-ray fluorescence (EDXRF)

Lower cost than for PGNAA-based alternatives

Combines traditional and on-line techniques.Tighter quality control at lowest possible cost.

Easily installed for vertical or ball mill

Traditional vs OnStream analysis

Analytical error

Preparation error

Sampling error

Traditionallaboratory

Analytical & sample

presentationerror

OnStream• The on-stream analyzer

monitors the process dynamics with:

high frequency and good high frequency and good precision & good accuracyprecision & good accuracy

• The lab analyzer establish the chemical level with:

high precisionhigh precision & high accuracyhigh accuracy

• Redundant structure

Samplingerror

OLX900 (1)

Smaller footprint of protective IP65 container

Smaller footprint of Smaller footprint of protective IP65 containerprotective IP65 container

Based on MiniPal QCBased on Based on MiniPalMiniPal QCQC

When two nearby sampling points

When two nearby When two nearby sampling pointssampling points

OLX900 (2)

When integrated withparallel composite sampling

& automatic sample transport

When integrated withWhen integrated withparallel composite samplingparallel composite sampling

& automatic sample transport& automatic sample transport

OLX900 (3)

Platform

Process flow

Analyzer head & electronics

PLC, signal I/O, electricalcomponents, pneumatics

Composite sampling;manual collection(Option)

Config 1 PS-SC screw sampler with excess return by gravity

Dosing Spoon, placedimmediately after sampler20 cc per sampling

Process flowProcess flow

Project specific height. Up to 3m tube &

1 beater included.

Fixed shape, gravity return profile

Primary sampler;Continuously running.Few litres per minute

Platform -1

Composite sampling;automatic collection(Option)

Platform

200 cc22

1 beater included.Process flowProcess flow

200 cc

Excess materialreturned to process Blower with

air sluice

Config 1 + parallel aut PSM-G samplingPS-SC screw sampler with excess return by gravity

Platform

Config 2 PS-SC screw sampler with excess return via blower

Excess materialreturned to process

Blower with air sluice

Primary sampler;Continuously running.Few liters per minute

1 beater included.

Process flow

ProcessProcessflowflow

Composite sampling;automatic collection(Option) Platform

200 cc22

1 beater included.

200 cc

air sluice

Config 2 + parallel aut PSM-G samplingPS-SC screw sampler with excess return via blower

Platform -1

Composite sampling;automatic collection(Option) Platform

200 cc22

1 beater included.

200 cc

air sluice

Config 2a + parallel aut PSM-C samplingPS-SC screw sampler with excess return via blower

Platform -1

Sometimes the upper dosing device may be eliminated. In this case the lower one services PSM-C and OLX900

Platform

• Config with one analyzer servicing two raw mills, two cement mills (or one raw mill and one kiln feed sampling point)

• Feasible, when horizontal distance between sampling points are less than say 10 m

• Y-piece connection for short hori- zontaldistances or sufficient installation height

• Sample tube inclination from vertical: preferably < 15 deg; maximum 30 deg

• Sampling in chutes or air slidessupported

• Very favorable price compared to two PGNAA’s for two raw mills

Mill 2 (or kiln feed)Mill 1

Project specific height. Up to 15 m tube above Y-piece included.Max 30 deg from vertical.

Beater (always Included)

Stop slide

Config 3 Dual PS-SC screw sampler with excess return via blower

Primary samplers;Alternatively running withstart 1-2 minutes before20 cc spoon sample taken.Few litres per minute

1 beater included.

Platform

Process flow

Config 4 PS-AS air slide sampler with excess return via blower

Process flow

Primary sampler;Intermittently operating.Start 20 secs before20 cc spoon sample taken.

1 beater included.

Platform

1 beater included.

200 cc

Primary sampler;Intermittently operating.Start 20 secs before20 cc spoon sample taken.

Config 4 + parallel aut air slide samplingPS-AS air slide sampler with excess return via blower

250 cc

Sometimes the upper dosing device may be eliminated. In this case the lower one services both mixer tank and OLX900

Platform

Mill 2 (or kiln feed)

Project specificheight. Up to 15 mabove Y-piece.Max 30 degfrom vertical.

Beater (always Included)

Stop slide

Config 5 Dual PS-AS air slide sampler with excess return via blower

Primary samplers;Alternatively running withstart 20 secs before20 cc spoon sample taken.Mill 1

1 beater included.

accumulated QCX system sales by Q2 2009:

+ 600 QCX Systems sold worldwide, hereof- 140 fully automated sample prep projects - 225 projects with automatic sample transport- 125 projects with on-line analysis

more than 35 years experience!

QCX – the market leader in the cement industry

QCX systems sale (cement)

010203040506070

1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007Oct

RoboLabAutoPrepSmall

End of Part 1

Control systems, 25%

Lab Automation, 22%

High control level, 16%

Instrumentation & Gas, 19%

Parts & Services, 18%

February 2010www.flsautomation.com

Product Segments

Process and Quality Control Solutions

Securing Our World Leadership Position Securing Our World Leadership Position through Innovation!through Innovation!

Enterprise focus

Managerial focus

Supervisory focus

Operational focus

Machinery focus

ACE:Adaptable

ControlEquipment

QCX:Quality control by

Computer andX-ray

PCI:Power &Control

Integration

ECS:ExpertControl &Supervision

AME:AdvancedMeasuringEquipment

PLC System Independence

Four major PLC brands supported Built-in dedicated high performance I/O drivers No add-ons or 3rd party software required No additional hardware required Mix and match as you please!

ABBModicon

SiemensAllen-Bradley

--------------------OPC-DA

ECS/ControlCentre -Flexible Operator Interface

Well-known standard operator interface Very flexible!

ECS : Advanced Process control / ECS : Advanced Process control / High Level controlHigh Level control

High Level Control

Limits

Optimum operation point

Operator

ECS ProcessExpert

High-Level Control in a control system environment

Does NOT replace the operator, but becomes his BEST assistant

Typically results of cement kiln applications:

Typically results of cement mill applications:

Production Increase

Fuel Savings Quality Improvement

3 – 5% 2 – 4% up to 30%

Production Increase Power Savings

Decrease Standard Deviation

3 – 8% 3 – 8% 10 – 20 %

Why High Level Control Can Benefit?

Small Numbers = Big Money(Calculation available on www.flsautomation.com-> High level control-Calculator)

Local ConditionsProduct Net Profit 15 EUR/tPower Cost 0,06 EUR/kWhFuel Cost 12 EUR/Gcal (coal)Kiln Operation Period 11 month/yearMill Operation Hours 20 hours/day

Kiln & Cooler Process Improve [%] Benefit EUR/YearProduction 2200 tons/day 0 0Specific Fuel Cons. 780 kcal/kg 0 0Specific Power Cons. 30 kWh/t 0 0

Cement Mill Improve [%] Benefit EUR/YearProduction 100 tons/hours 0 0Specific Power Cons. 33 kWh/tons 0 0

ECS/ProcessExpert- Open Toolbox

Fuzzy Logic

Free Programs

MATLABKalman Filter

Filter

The building blocks to develop an application

Browser

Toolbox, controller overview

Editor

Easy overview of execution status

Controller design & implementation

An open environment with– Pre-define objects for parameterisation– Easy environment for programming (~ Visual Basic)– Open interface to MATLAB– Model Predictive Control (MPC)- for eg.Kiln Multifuel

Process inputProcess analoq outputProcess digital outputFree programmingFuzzy-logic rule blocksControl objectivePriority managementHierarchical structureKey Performance IndexMATLAB linkRecipe switchingKalman FilterMPC designState-Space simulator

Various kilns, e.g. In-line calciner, Separate line calciner,…

Typically grate coolers

Dedicated MultiFuel application

(Soft sensors on NOx and free lime)

Vertical Roller Mills with special attention to the vibrations

Raw meal grinding, with QCX/BlendExpert for feeder control

Cement grinding, with soft-sensor on fineness

On-line fineness analysis and control

Ball mills for raw meal, cement or coal grinding

Raw meal grinding with QCX/BlendExpert for feeder control

Cement grinding, with soft-sensor on fineness

On-line fineness analysis and control

Available Applications

Pyro Process

Control & Optimisation

Handling 40+ measurement every 5 sec is a Handling 40+ measurement every 5 sec is a ChallengeChallenge

Torque, AMPs

Calciner outlet temp.O2, CO, NOx

Kiln Feed

O2, CO, NOx

Calciner Fuel

Kiln Fuel

ID-Fan SpeedDamper Position

TAD Pos.

Free LimeAnalysis

Hood Temp

TA Temp.

O2, CO, NOxKiln Inlet Temp

Spyrometer (1-n)

Pre-heater outlet temp.

Kiln Inlet Gas Analyser Status

Pre-heater Gas Analyser Status

Calciner Gas Analyser Status

Process Status MeasurementsProcess Control Parameters

Kiln Speed

Under-grate pressure (1-n)

Fan Speed

Grate speed

Kiln & Cooler Controller,1

Quality ControlTypically Free-lime and Litre-weight

Production optimisation

Lowest possible fuel and power consumption

Handling the up-set conditionsHigh CO in kiln inlet and pre-heaterRing fallPre-heater high temperature

Optional:On-line estimation of free limeOn-line estimation of NOx

Functions

Kiln & Cooler Controller,2

Control actions every 10+ seconds

Multi-input, multi-output strategyPriority Management SystemControl groups using fuzzy logic /MPC

Performance indicators:Production level,Kiln stability,Heat consumptionDraft stability,Burning zone temp.

Open access to the Toolbox for add-on implementations

Features

Examples From Real Life…

Calciner Outlet Temp. Process Value [°C] Calciner Outlet Temp. Set-point [°C]

Calciner coal feed [t/h]

Calciner outlet temp. control, Ethiopia 2001

Reduction in Heat Consumption

Before After

Multiple Fuel Burning

Energy

Requirement

Kiln Multiple Fuel

Fuel 1, x$

Fuel 2, y$

Fuel 3, -z$

Cost-effective

Multi-fuel Controllerhandling chemical, environmental and

equipment properties

Multi-Fuel Application

Optimum fuel design for “the best mix” respecting Fuel cost, feeder limitations and dynamic, chemistry and emission targets

Configurable to any number of fuel Automatic fuel substitution

Prediction of final heat and chemistry in the combustionModel-base Predictive Controller (MPC)

Adjustable optimisation strategy with weight factors

Can be integrated as stand-alone application to 3rd party or manual kiln controller

Functions

Features

Basic target for the customer is to maximize use of lowest cost fuel within the Environmental Rules

Ball Mill

Control & Optimisation

• Raw meal grinding

• Cement grinding

• Coal grinding

Example: Cement Mill Unit

Reject Flow

Fresh Feed

Elevator Load

Folaphone

Mill Power

Product Flow

Raw materials

Product QualityBlaine(on-line) Particle SizingSO3LOI

Status MeasurementsManipulated ParametersManipulated Parameters, if available

Separator Air

Water Inlet, Outlet

Mill Air

Separator Speed

Product Flow,2

Cement Mill Controller

Quality ControlBlaine, Particle Size Characteristic, SO3, LOI

On-line estimation of fineness values

Recipe handling with automatic switch-over

Control actions every minute

Multi-input, multi-output strategyModel-based Predictive Controller (MPC)Adjustable optimisation strategy with weight factors

Performance indicators: Production level and Mill stability

Open access to the Toolbox for add-on implementations

Functions

Features

Interlocking on controller availability

Measurements to involve, predict and control

Automatic recipe handling

Actions planed and executed by the MPC-based controller

Cement Mill Control, Operator Interface

Key Performance Indexes

Process Optimisation Enabling

Cement Mill Control, Recipe Management

…also control constraints can be adjusted individually to match

operation conditions

“Elevator Power” as an indication of production, was here selected to be more important than the second objective, i.e. fineness parameter

If a measurement “Status” is evaluated as invalid, its model-based prediction can automatically be used as replacement measurement

Production optimisation tuning

Cement Mill Control, Controller Tuning

Remote Monitoring Services…

FLSmidth Automation offer remote monitoring services:

Process Troubleshooting and Support

Software Maintenance

Engineering and Optimization Services

ECS : Management Information ECS : Management Information systemssystems

If you cant measure it you cant If you cant measure it you cant improve itimprove it

Solutions for every operational level

Business Management

Business-critical management information systems

Control

Automation systems that run all plant processes

Sensors & Actuators

Process-enhancing components that provide real-time data

Optimisation

Process-optimising high-level control solutions

Supervision

Applications for monitoring and controlling systems

FLSmidth Automation Solution Pyramid

ECS/PlantGuide - Benefits

The right Information to The right person at The right time inThe right form

Plant Status AvailableAnywhere You Are…

Data AVAILABILITY

Data RELIABILITY

ECS/PlantGuide – A Gateway to Plant Data

QCXSCADA

PLG Enterprise -Network Configuration

PlantGuide-Web at office & corporate level

A Web browser-based user-interface Simple process mimics with latest values Download any pre-generated report View trends View KPIs HTML pages

Configuration Features Users organized in groups Access control at page level Flexible page design tool

Data presentation

Main PLG Web Features

Mimic view– Live update, 10 sec

Trend– 24 hour line plot

Main PLG Web Features

Report Download-Excel, Pdf a.o.

Trend-One month Bar chart

FLSmidth Automation

Building trust Building trust in automationin automation

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