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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 -
November 2009QCX/OLX900 4June 2008www.flsautomation.com
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
0%
Other industries13%
Other industries -ind irect
0%
Af termarket21%
November 2009QCX/OLX900 6
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
November 2009QCX/OLX900 7
Control systems, 25%
Lab Automation, 22%
High control level, 16%
Instrumentation & Gas, 19%
Parts & Services, 18%
February 2010www.flsautomation.com
Product Segments
Source: Net Contribution Calendar Year 2009
November 2009QCX/OLX900 8June 2008www.flsautomation.com
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
November 2009QCX/OLX900 9
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.
November 2009QCX/OLX900 10
How can we help you.?
ECS- Process Control Solutions
QCXQCX -- QualityQuality ControlControl SolutionsSolutions
November 2009QCX/OLX900 11
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
November 2009QCX/OLX900 12
.. central lab .. central lab automation automation concept ...concept ...
QCXQCX is ...is ...collection & collection & administrationadministrationof analysis data of analysis data and and quality controlquality control
November 2009QCX/OLX900 13
PGNAA
PGNAA
XRFQCX/OnStream
LOI
FCaO
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
November 2009QCX/OLX900 14
Raw mealSilo Cement
Silos
Kiln
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
November 2009QCX/OLX900 15
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
November 2009QCX/OLX900 16
Mix optimizationalgorithms and utilities
On-lineProductionAccounting
Analysisdata
on-li
ne
PGNAA
process
on-line QC applications
BlendExpert-Mill
labo
rato
ry
XRF
XRF
BlendExpert-AQL
Blast & equipment
data
on-line tracking & mappingmanual consequential calculations(add-on module for QCX/BlendExpert-Pile)
quarry
GPS
BlendDesigner
Datacapture
off-line design and static simulation
QC/QA management
QCX
QCX mix control modularityQCX mix control modularity
BlendExpert-PileLo
ngitu
dina
lBu
cket
Exc
avat
orC
ircul
ar
November 2009QCX/OLX900 17
Mix optimizationalgorithms and utilities
On-lineProductionAccounting
Analysisdata
on-li
ne
PGNAA
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
November 2009QCX/OLX900 18
BlendExpert-Pile
BlendExpert-MillBlendExpert-AQL
BlendDesigner
4 strong applications
BlendMaster-Pile
BlendMaster-Mill
November 2009QCX/OLX900 19
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
On-lineProductionAccounting
Analysisdata
QCX/BlendDesigner
Data capture
QCX/BlendExpert-AQL
Blast & equipment
data
+500 sold applications!
November 2009QCX/OLX900 20
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
November 2009QCX/OLX900 21
0-360o
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
November 2009QCX/OLX900 22
OLX900 AnalyzerOLX900 Analyzera QCX/a QCX/OnStreamOnStream productproduct
Platform
Process flow
6L
Process flow
November 2009QCX/OLX900 23
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
November 2009QCX/OLX900 24
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
November 2009QCX/OLX900 25
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
November 2009QCX/OLX900 26
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
November 2009QCX/OLX900 27
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
November 2009QCX/OLX900 28
When two nearby sampling points
When two nearby When two nearby sampling pointssampling points
OLX900 (2)
November 2009QCX/OLX900 29
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)
November 2009QCX/OLX900 30
Platform
Process flow
1
2
3
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
22
16L
3
November 2009QCX/OLX900 31
Platform -1
1
2
3
Analyzer head & electronics
PLC, signal I/O, electricalcomponents, pneumatics
Composite sampling;automatic collection(Option)
Platform
200 cc22
1
Dosing Spoon, placedimmediately after sampler20 cc per sampling
Project specific height. Up to 3m tube &
1 beater included.Process flowProcess flow
200 cc
3
Excess materialreturned to process Blower with
air sluice
Mixer
Config 1 + parallel aut PSM-G samplingPS-SC screw sampler with excess return by gravity
November 2009QCX/OLX900 32
Platform
1
2
3
Analyzer head & electronics
PLC, signal I/O, electricalcomponents, pneumatics
Composite sampling;manual collection(Option)
Config 2 PS-SC screw sampler with excess return via blower
22
16L
Dosing Spoon, placedimmediately after sampler20 cc per sampling
Excess materialreturned to process
Blower with air sluice
Primary sampler;Continuously running.Few liters per minute
Project specific height. Up to 3m tube &
1 beater included.
Process flow
ProcessProcessflowflow
3
November 2009QCX/OLX900 33
1
2
3
Analyzer head & electronics
PLC, signal I/O, electricalcomponents, pneumatics
Composite sampling;automatic collection(Option) Platform
200 cc22
1
Dosing Spoon, placedimmediately after sampler20 cc per sampling
Project specific height. Up to 3m tube &
1 beater included.
Process flowProcess flow
200 cc
Excess materialreturned to process Blower with
air sluice
Config 2 + parallel aut PSM-G samplingPS-SC screw sampler with excess return via blower
Platform -1
3
Mixer
November 2009QCX/OLX900 34
1
2
3
Analyzer head & electronics
PLC, signal I/O, electricalcomponents, pneumatics
Composite sampling;automatic collection(Option) Platform
200 cc22
1
Dosing Spoon, placedimmediately after sampler20 cc per sampling
Project specific height. Up to 3m tube &
1 beater included.
Process flowProcess flow
200 cc
Excess materialreturned to process Blower with
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
3
Mixer
November 2009QCX/OLX900 35
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
Excess materialreturned to process
Blower with air sluice
Primary samplers;Alternatively running withstart 1-2 minutes before20 cc spoon sample taken.Few litres per minute
Project specific height. Up to 3m tube &
1 beater included.
22
16L
3
November 2009QCX/OLX900 36
Platform
Process flow
1
2
3
Analyzer head & electronics
PLC, signal I/O, electricalcomponents, pneumatics
Composite sampling;manual collection(Option)
Config 4 PS-AS air slide sampler with excess return via blower
Dosing Spoon, placedimmediately after sampler20 cc per sampling
Process flow
Excess materialreturned to process
Blower with air sluice
Primary sampler;Intermittently operating.Start 20 secs before20 cc spoon sample taken.
Project specific height. Up to 3m tube &
1 beater included.
22
16L
3
November 2009QCX/OLX900 37
Platform
22
1
Dosing Spoon, placedimmediately after sampler20 cc per sampling
Project specific height. Up to 3m tube &
1 beater included.
200 cc
Excess materialreturned to process
Blower with air sluice
3
Mixer
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
November 2009QCX/OLX900 38
Platform
Mill 2 (or kiln feed)
Project specificheight. Up to 15 mabove Y-piece.Max 30 degfrom vertical.
Beater (always Included)
Stop slide
6L
Config 5 Dual PS-AS air slide sampler with excess return via blower
Excess materialreturned to process
Blower with air sluice
Primary samplers;Alternatively running withstart 20 secs before20 cc spoon sample taken.Mill 1
Project specific height. Up to 3m tube &
1 beater included.
November 2009QCX/OLX900 39
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
November 2009QCX/OLX900 40
End of Part 1
November 2009QCX/OLX900 41
Control systems, 25%
Lab Automation, 22%
High control level, 16%
Instrumentation & Gas, 19%
Parts & Services, 18%
February 2010www.flsautomation.com
Product Segments
Source: Net Contribution Calendar Year 2009
November 2009QCX/OLX900 42June 2008www.flsautomation.com
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
November 2009QCX/OLX900 43
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
November 2009QCX/OLX900 44
November 2009QCX/OLX900 45
November 2009QCX/OLX900 46
ECS/ControlCentre -Flexible Operator Interface
Well-known standard operator interface Very flexible!
November 2009QCX/OLX900 47June 2008www.flsautomation.com
ECS : Advanced Process control / ECS : Advanced Process control / High Level controlHigh Level control
November 2009QCX/OLX900 48February 2010www.flsautomation.com
High Level Control
Limits
Optimum operation point
P1
P2
Operator
ECS ProcessExpert
November 2009QCX/OLX900 49February 2010www.flsautomation.com
High-Level Control in a control system environment
Does NOT replace the operator, but becomes his BEST assistant
November 2009QCX/OLX900 50February 2010www.flsautomation.com
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?
November 2009QCX/OLX900 51
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
November 2009QCX/OLX900 52
ECS/ProcessExpert- Open Toolbox
MPC
Fuzzy Logic
PID
Free Programs
MATLABKalman Filter
Filter
The building blocks to develop an application
November 2009QCX/OLX900 53
Browser
Toolbox, controller overview
Editor
Easy overview of execution status
November 2009QCX/OLX900 54
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
November 2009QCX/OLX900 55
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
November 2009QCX/OLX900 56
Pyro Process
Control & Optimisation
November 2009QCX/OLX900 57
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
November 2009QCX/OLX900 58
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
November 2009QCX/OLX900 59
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
November 2009QCX/OLX900 60
Examples From Real Life…
November 2009QCX/OLX900 61
Calciner Outlet Temp. Process Value [°C] Calciner Outlet Temp. Set-point [°C]
Calciner coal feed [t/h]
Calciner outlet temp. control, Ethiopia 2001
November 2009QCX/OLX900 62
Reduction in Heat Consumption
Before After
November 2009QCX/OLX900 63
Multiple Fuel Burning
November 2009QCX/OLX900 64
Energy
Requirement
Kiln Multiple Fuel
Fuel 1, x$
Fuel 2, y$
Fuel 3, -z$
Cost-effective
mix
Multi-fuel Controllerhandling chemical, environmental and
equipment properties
November 2009QCX/OLX900 65
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
November 2009QCX/OLX900 66
Ball Mill
Control & Optimisation
• Raw meal grinding
• Cement grinding
• Coal grinding
November 2009QCX/OLX900 67
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
November 2009QCX/OLX900 68
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
November 2009QCX/OLX900 69
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
November 2009QCX/OLX900 70
Cement Mill Control, Recipe Management
…also control constraints can be adjusted individually to match
operation conditions
November 2009QCX/OLX900 71
“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
November 2009QCX/OLX900 72
Remote Monitoring Services…
FLSmidth Automation offer remote monitoring services:
Process Troubleshooting and Support
Software Maintenance
Engineering and Optimization Services
November 2009QCX/OLX900 73June 2008www.flsautomation.com
ECS : Management Information ECS : Management Information systemssystems
November 2009QCX/OLX900 74June 2008www.flsautomation.com
If you cant measure it you cant If you cant measure it you cant improve itimprove it
November 2009QCX/OLX900 75
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
November 2009QCX/OLX900 76February 2010www.flsautomation.com
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
November 2009QCX/OLX900 77February 2010www.flsautomation.com
ECS/PlantGuide – A Gateway to Plant Data
QCXSCADA
November 2009QCX/OLX900 78
PLG Enterprise -Network Configuration
November 2009QCX/OLX900 79
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
November 2009QCX/OLX900 80
Main PLG Web Features
Mimic view– Live update, 10 sec
Trend– 24 hour line plot
November 2009QCX/OLX900 81
Main PLG Web Features
Report Download-Excel, Pdf a.o.
Trend-One month Bar chart
November 2009QCX/OLX900 82
FLSmidth Automation
Building trust Building trust in automationin automation