Global Product Group Cement, CPM Cement cpmplus Expert Optimizer Designed by process experts, customized to your needs
ABB s CPM portfolio for cement industries Thermal Energy Economic Process Optimization Electrical Energy Production Scheduling -Performance Indicators -Production Performance -Costs MM/SD PP-PI SAP PM QM Control Expert Optimizer Kilns, Calciner & Cooler Stockpile Blending Mills Optimization Raw Mix Preparation Alternative Fuels Cement Blending Information Knowledge Manager Production Information Mngt. Process Data Mngt. Production Accounting Enterprise Connectivity LIMS Downtime Mngt. Laboratory Automation Quality Robotics Process Control August 5, 2015 Slide 2
cpmplus Expert Optimizer ABB s advanced process control solution for your cement plant Your challenges Need for optimal productivity Need for reduced energy consumption Shift-to-shift variations Variable raw material and fuel quality Our solution Advanced Process Control solution providing you with modern tools, such as Model Predictive Control, graphical program editor etc. Pre-defined modules covering the entire cement process August 5, 2015 Slide 3
Your benefit Stabilize then optimize Manual Automatic using Expert Optimizer Production Rate Optimized setpoint Optimize Benefits due to optimization Stabilize Manual setpoint Time August 5, 2015 Slide 4
Technology in cpmplus Expert Optimizer Expert Optimizer tools Fuzzy algorithms Graphical control builder MPC engine APC model builder Data processing Empirical models from data sets Arithmetic and logic operations Soft sensors Graphical MPC models (linear and non-linear) Soft sensor models Fuzzy algorithms to create multivariable controllers Soft sensors to estimate hidden variables or create back-up signals Linear and non-linear Model Predictive Control (MPC) capabilities Graphical and empirical modelling Easy to use graphical configuration General calculations: arithmetic, Boolean, text etc. State Machines Windows-based HMIs: Drag & drop configuration August 5, 2015 Slide 5
cpmplus Expert Optimizer Cement applications Kiln, calciner and cooler control Coal mill control Stockpile blending Raw material blending Raw mill control Cement blending Cement mill control August 5, 2015 Slide 6
Kiln, calciner and cooler optimization Features and benefits Output or Freelime Features Burning zone temperature optimization Output vs BZT Freelime vs BZT Combustion optimization Alternative fuel maximization Output optimization Output Benefits Reduced number of mill stops Increased output EO Operator Reduced specific power Reduced quality variability August 5, 2015 Slide 7 BZT Return to overview
Material grinding Features and benefits Mill output Output Features Mill load and throughput optimization Fineness control Operator EO Automatic product type switching Supports vertical mills, ball mills and hybrid circuits Benefits Reduced number of mill stops Increased output Reduced specific power Reduced quality variability Mill fill August 5, 2015 Slide 8 Return to overview
Material blending Feature and benefits Features Mix control with laboratory samples and/or online analyzers Optimization of material costs Maximization of additives in finished cement Benefits Reduced fluctuations in blended material composition Reduced material costs Improved kiln operation due more homogeneous raw material Quality Pre-blending bed Feeders Raw Mill Continuous homogenization silo Quarry Kiln Long term fluctuations Middle term fluctuations Short term fluctuations Short term fluctuations "Zero" August 5, 2015 Slide 9 Return to overview
cpmplus Expert Optimizer A reliable solution for increased productivity Typical values we deliver to customer Increased output 1% to 5% Reduced fuel consumption 1% to 5% Reduced emission levels 3% to 5% Reduced electricity consumption 1% to 5% Reduced quality variability 10% to 20% Reduced refractory consumption 10% to 20% August 5, 2015 Slide 10
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