Cement, Energy and Environment

to be specifically tailored to the needs of each plant by incorporating the best control knowledge. Union Bridge plant solution Automatic start-up of an OK mill A novel part of the control strategy for this installation is the 'auto-start' function. A smooth and controlled startup is essential for vertical mills to achieve rapid process stability and to minimize machinery wear. To accomplish this, the ECS/ProcessExpert transmits the startup commands to the mill control system in the proper sequence while manipulating and stabilizing the feed, separator speed, water injection and fan damper position. Once the mill is stabilized, the automatic startup finishes and the optimization strategy takes control of the mill. Optimized process The optimization strategy is based on Model Predictive Control (MPC) technology which creates a simplified model of the process. The MPC ·controller is a flexible solution that usually aims to maximize the feed according to quality and process constraints, mainly mill vibration, main motor power and mill differential pressure. The Controller can , however, be tasked with stabilizing the mill at reduced capacity when the need arises. Proven results To measure the results, a test protocol was defined and executed by the Union Bridge plant and FLSmidth Automation. The results clearly described the benefits on the ECS/ProcessExpert and the accomplishment of the main goals. The main results follow: o Increased production rate by 4.5 per cent o Reduced Blaine Standard deviation by 36 per cent while maintaining target o Reduced shutdowns . process-related Adelaide Brighton, Birkenhead, Australia Adelaide Brighton Cement installed an ECS/FuzzyExpert system running on a Digital VAX Workstation with four terminals in 1995, to control their kiln and two cement mills. The ECS/FuzzyExpert system was upgraded to ECS/ProcessExpert running on a Window XP Professional server with four clients. The programmes from the old FuzzyExpert system were reviewed with some important functions carried through and added to the standard ECS/ProcessExpert suite at that time. The ProcessExpert has a runtime factor of 94 per cent for the dual string dry-process kiln. Similarly, the cement mills No 1 and 6 have on-time factors of 96.2 per cent and 94.5 per cent. Central to achieving these excellent run times is the 13