Advanced process control

for the cement industry

ECS/ProcessExpert
®
2 3

Why use advanced

process control?

Advanced process control from When a cement company wants to Using a sophisticated toolbox and History FLSmidth – the process
FLSmidth ensures that cement get the most out of its cement plant, specialized application modules, For 40 years, FLSmidth has been a knowledge experts
Expert Control and Supervision (ECS) ECS/ProcessExpert continuously Advanced Process Control
plants perform better, resulting pioneer in high-level expert control FLSmidth’s international team of
is the key. performs complex analyses of a Operator
in increased stability and higher systems for cement applications. process experts designs solutions
plant’s process conditions. ECS/ProcessExpert is a development specifically for cement applications.
profitability.
FLSmidth’s ECS/ProcessExpert of ECS/FuzzyExpert, which was the With more than 40 years of plant
provides advanced process control This enables it to make adjustments first expert system engineering automation experience, FLSmidth has
Direct Benefits and optimization for cement plants, to the process more frequently and platform in the cement industry. It is installed over 700 control systems
• Up to 8% higher production so they can achieve maximum reliably than a human operator can. based on the latest developments and 450 laboratory systems – and
• Up to 6% lower fuel/energy efficiency and higher profitability. Installed on a standard PC, the within proven technologies, such as understands the needs of today’s
consumption system has an easy-to-interpret Fuzzy Logic and Model-based cement plants.
ECS/ProcessExpert stabilizes the graphical interface and advanced Predictive Control. The control
• Up to 30% lower standard deviation of
plant, optimizes the production, alarm and trend capabilities that are strategies in ECS/ProcessExpert are FLSmidth is a world leader in building
quality

Li
manages and corrects process easy to use and manage – and it’s

m
based on four decades of experience and maintaining cement plants, and

it
• Payback of investment in less than disruptions and minimizes wear on compatible with most other plant

s
in cement control and optimization that first-hand experience plays an
a year (depending on specific the plant’s equipment – all to ensure control systems. projects. important role when developing
applications) optimum plant performance. By innovative automation solutions that
improving equipment availability and enhance the production capabilities
Indirect Benefits utilization, the system helps reduce of customers’ plants.
• Long-term stability operational and maintenance costs.
• Reduced equipment wear
• Minimized downtime Operator vs computer-based decisions
• Reduced maintenance costs

Vertical Roller Mill Application Multi-fuel Application Kiln & Cooler Application Ball Mill Application
Page 10 Page 6 Page 4 Page 8
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Kiln & cooler

application

An unstable kiln and cooler Control challenges Corrective actions made by Upset and process are handled by changing the Parameters controlled
leads to inefficient production Controlling a cement kiln has always ECS/ProcessExpert typically include a customized control speed of the ID and EP fans. • Kiln feed, speed and fuel
and inconsistent clinker quality. been a challenging task for cement combination of changes to fuel In the event of upset conditions such Other examples of upset conditions • Calciner fuel
ECS/ProcessExpert stabilizes the plant operators. These days, a injection, kiln feed and speed, as well as fall of coating in the kiln, include high preheater exit CO, cooler
• ID fan speed
computer-based pyro control system as fan speeds. The result is stable ECS/ProcessExpert reduces kiln feed bed build up and coal mill stoppage
kiln and cooler using advanced • Cooler grate and fan speed
is not merely nice to have, it is a temperature control in the calciner, and speed, while continuously affecting the coal feed to the kiln.
process control, resulting in
practical necessity. Both the inherent stable filling degree in the kiln, stable monitoring kiln conditions to ensure
increased production, reduced
complexity of the pyro process and cooler operation as well as consistent smooth and fast recovery. ECS/ProcessExpert is easily Parameters monitored
cyclone blockages and kiln ring clinker quality.
the far-reaching consequences of A raw mill stoppage is another customized to plant specific • Kiln inlet gas analyzer measurements
formations, while delivering requirements, such as emissions
off-spec clinker, faulty operating example of an upset condition • Kiln temperatures and pressure
consistent clinker quality. Optimization control control using ammonia injection.
conditions and production shutdowns handled by ECS/ProcessExpert,
Once the process has been stabilized, • Kiln torque
make an automated control system whereby gas pressure changes in the
Benefits indispensable. Kiln process control is ECS/ProcessExpert will seek to • Cooler pressure and temperatures
• Production increased by up to 4% optimize the process by operating as
divided into three control strategies;
• Reduced cyclone blockages and kiln normal, optimization and close as possible to the limits. In
ring formations upset control: optimization control, free lime is kept
• Consistent quality with a reduction closely on target, permitting an
ID-fan speed. Damper pos.
in standard deviation by up to 30% Normal control increase in the free lime target.
02, CO, NOx. Pre-heater outlet temp.
• More stable operation ECS/ProcessExpert initially operates in
normal control mode, where the In addition, ECS/ProcessExpert also
Calculate your own benefits online monitors the lime saturation factor
process is stabilized. Stabilization is a
using the ECS/ProcessExpert benefit (LSF) in the kiln feed and Kiln feed
prerequisite for optimization control
calculator at www.flsmidth.com/pxp automatically adjusts the free lime
and is thus a key element of the Process status measurements
overall control strategy. The normal target, to avoid over burning Manipulated parameters
control strategy stabilizes the of clinker. ECS/ProcessExpert
Manipulated parameter, if available
preheater, kiln and cooler, using a consequently ensures lower fuel
range of calculated key performance consumption and minimizes the risk
indices. These indices include the of off-spec clinker. The kiln and cooler
Burning Zone Temperature Index, Kiln can be further optimized using a Calciner outlet temp.
Operation Stability Index and the Kiln multi-fuel add-on application (see 02, CO, NOx
Heat Consumption Index. page 6 for more information).
TAD pos.
Calciner fuel TA temp. Kiln fuel

Hood temp.
Spyrometer

02, CO, NOx Free lime analysis

Kiln inlet temp. Torque, AMPs
Kiln speed Fan speed

Under-grate pressure Grate speed

6 7

Multi-fuel
application

Higher focus on cost reduction Control challenges This is achieved by a predictive

using alternative fuels causes With increased focus on cost technique to handle fuel feeder
disturbances in the pyro process, reductions, many cement plants have constraints and dynamics, while
where operators need support started using alternative fuels for kiln minimizing combustion disturbances
and/or calciner firing. This has created in the kiln.
from advanced process
control systems. more challenges for the operation of
a kiln because of the different The multi-fuel application is best
characteristics of different alternative implemented as an integrated add-on
fuels such as calorific value, moisture to a kiln and cooler application, but
Benefits content and chemical composition. can also be installed as a stand-alone
• Better transition during loss of fuel, application.
ECS/ProcessExpert ensures successful
resulting in a stable kiln process
management of alternative fuels
• Higher utilization of alternative fuels without comprising stability The multi-fuel application may be
• Any number of alternative fuels handled or quality. integrated with an emission
monitoring system such as
• Better compliance with environmental
restrictions Optimization control ECS/StackGuide to incorporate
The customizable multi-fuel emission data, ensuring that
• Investment payback in less than environmental limits are
application ensures the best possible
one year not exceeded.
mix of available fuels based on costs,
Calculate your own benefits online using heat value and chemistry implications.
the ECS/ProcessExpert benefit calculator at The application is designed to deliver Upset control
www.flsmidth.com/pxp a consistent total heat value at the Burning alternative fuels may result in
lowest possible cost. sudden drops of one or more fuels.
ECS/ProcessExpert handles this
condition by quickly compensating
with other fuels, ensuring a
continuous and stable process.

Parameters controlled
• Ratio between fuels

Parameters monitored
• Fuel costs
• Fuel feeder or environmental
limitations
• Current feed rate of different fuels
• Chemical analysis of fuels
• NOx and burning zone temperatures
• Emissions data from optional
emissions monitoring system
(ECS/StackGuide)
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Ball mill application

Ball mill grinding is a highly Control challenges inefficiency. ECS/ProcessExpert aims The result is stable operation, reduced measurements with second priority Parameters controlled
energy consuming process and To obtain lowest possible power to achieve the best possible grinding energy consumption and increased signals or estimated values in order to • Feed and fineness control by fresh
the ECS/ProcessExpert Ball mill consumption, maximum production efficiency through an advanced Multi- production. continue operations. This temporary feed and separator speed
application is built to meet the and lowest possible quality variation, Input Multi-Output (MIMO) control measurement replacement can also • Feeder ratio control for quality
increasing demand for maximum a conventional control solution with strategy using a Model-based Optimization control be selected manually by the operator
• Mill draft
PID loops is insufficient. Process Predictive Control (MPC) technique. The ball mill application automatically if a device is temporarily taken out for
production with minimum power • Water flow
delays (for example fineness analysis adjusts fresh feed, depending on maintenance.
consumption while minimizing
delay, material transportation) cannot Normal control clinker grindability, while ensuring the • On-line process state estimation
variations in quality. In a conventional closed circuit desired blaine or fineness. Automatic
be handled well by PID's.
grinding plant, separator speed and This ensures that the best throughput recipe handling Parameters monitored
Furthermore, the process contains fresh feed are the main control and quality is maintained for a For cement grinding processes with
• Product quality such as blaine or
Benefits internal couplings. For example, the parameters. The MPC controller given recipe. different types of cement, efficient
online particle size analyzer, SO3, LOI.
• Up to 6% increase in production separator speed not only impacts the frequently calculates new set points changeover between products is
• Separator and fan speed
• Up to 4% reduction in ball mill specific fineness, but also the mill filling level for the two parameters. Upset control crucial in product optimization.
In the event of mill jamming, the • Fresh and reject feed
power consumption through the reject flow. Therefore, a
change in one of the PID loops causes The calculation is based on application will ensure rapid action to ECS/ProcessExpert includes an • Mill Folaphone or elevator power
• Up to 30% reduction in quality variations
disturbance in the other PID loop. The minimizing a so called "cost-function" achieve optimum recovery, by efficient system for definition and • Draft and temperature
• Minimal product change-over time meaning minimum deviation from reducing the feed and monitoring the configuration of cement recipes. The
two PID loops are consequently often • Feeder response to a given setpoint
between recipes production targets and minimum mill until normal conditions are application enables the operator to
in conflict to reach their own
Calculate your own benefits online using objective. changes of separator speed and restored. If a process measurement is change production by merely
the ECS/ProcessExpert benefit calculator at fresh feed. declared invalid (for example due to selecting a recipe number. The
www.flsmidth.com/pxp This lack of coordinated action causes The weight factors for targets are hardware failure), the controller will automatic procedure ensures
undesired disturbances and operation used to prioritize between objectives. automatically replace the minimum changeover time.

Mill air
Seperator
Seperator air
speeed
Product flow

Product flow

Raw materials Status measurements

Manipulated parameters
Manipulated parameters
Reject flow Elevator load
(if available)

Fresh feed

Product Quality Folaphone Mill power

Blaine
(On-line) Particle sizing
SO3
LOI Water inlet / outlet
10 11

Vertical roller mill

application

Vertical roller mills are Control challenges The target optimization module con- The typical manipulated setpoints of a Mill auto-start Parameter summary
increasingly being used in the Among the operational challenges of tinuously seeks to maximize the pro- vertical roller mill are separator speed, A novel part of the ECS/ProcessExpert • Feed and fineness control by fresh
cement industry due to their a vertical roller mill are the fast duction within the allowed opera- fresh feed and mill fan. However, the control strategy for vertical roller feed and separator speed
higher efficiency. Fully automatic dynamics of the process. Compared tional limits. selection of process measurements, mills, is the auto-start function. A • Feeder ratio control for quality
to ball mills with dynamics changing This optimization ensures that the ini- control variables and setpoints is smooth and controlled start-up is
control of the vertical mill • Mill draft
in 15-20 minutes, vertical roller mills tial recipe targets are adjusted customized to the given process essential for mills to rapidly achieve
will improve the operational • Water flow
have dynamics changing in 2-4 according to the given conditions of configuration of the mill. process stability and to minimize
capabilities and efficiency of • On-line process state estimation
minutes. The fast dynamics the process such as raw material machinery wear. To accomplish this,
the mill. grindability. Upset control
necessitate even closer attention to the system transmits the start-up
the process conditions and taking In the event of mill vibrations, commands to the mill control system Parameters monitored
corrective action in time. Predictive process control ECS/ProcessExpert immediately takes in the proper sequence, while • Product quality such as blaine or
Benefits Based on a mathematical multi-input corrective action by reducing mill manipulating and stabilizing key online particle size analyzer, SO3, LOI.
• Up to 6% increase in production Other challenges include changes in multi-output model of the process, feed, resulting in optimum bed controlled variables, such as feed,
• Separator and fan speed
• Up to 4% reduction in specific power the grindability of material and water which describes delays and dynamics, thickness. If a process measurement is separator speed and fan damper
future conditions of the process are declared invalid (for example due to • Fresh and reject feed
consumption injections causing mill vibrations position. Once the mill is stabilized,
which may result in mill shutdown. predicted and optimum set points to hardware failure), the controller will the automatic start-up finishes and • Mill bed level thickness, power and
• Up to 30% reduction in quality variations
reach the targets are planned and automatically replace the the normal strategy takes control of differential pressure
• Tight control of vibrations to avoid mill
shutdowns
Optimization control implemented. The planned setpoints measurements with second priority the mill. • Draft and temperature
An advanced mill controller continu- are continuously updated due to the signals or estimated values, in order
• Feeder response to a given setpoint
• Minimal product change-over time ously monitors and adjusts the mill to differences between the process to continue operations. The main benefits coming from this
between recipes comply with the operational targets. variables predicted and measured. This temporary measurement module are:
• Simplified mill start-up When the mill reaches a stable level The setpoint calculation is based on a replacement can also be selected • Simplified and consistent mill
Calculate your own benefits online using of operation and the targets are ful- so-called optimization cost function manually by the operator if a device is start-up for operators
the ECS/ProcessExpert benefit calculator at filled, a high-level target optimization over the receding prediction horizon, temporarily taken out for • Reduced mill start-up time
www.flsmidth.com/pxp procedure calculates a new set of which seeks to minimize deviation maintenance.
optimum targets. from production targets.

Raw materials
Seperator Mill fan
speeed

Total fresh feed

Product flow
Status measurements Product fineness
Manipulated parameters Preassure difference
Elevator load Water spray
Mill vibration
Bed thickness

Mill power
12 13

Optimizing cement processes with

cutting-edge technology

Designed by process How does it work? In addition, ECS/ProcessExpert supports Measurement

and automation experts • Measurement validation: All the industry standard OPC UA, enabling replacement
specifically for cement parameters are validated before being integration with most existing control As another advantage of on-line
applications, used inside the system systems. estimation, if a process measurement is
ECS/ProcessExpert’s many • K
 PI´s: Provides visualization of the declared invalid (for example due to
innovative technologies process department status so Control system features hardware failure), the controller will
deliver flexibility and operators can monitor the system and ECS/ProcessExpert has built-in control automatically replace the measurements
generate reports system features such as long-term with the estimated values in order to
advanced process control.
historian with trending, alarm and event continue operations. This temporary
• O
 nline testing: The controller
As a leader in cement plant automation, management as well as a sophisticated measurement replacement can also be
behaviour can be tested in an on-line
FLSmidth continuously invests in HMI for graphical process selected manually by the operator if a
environment using the so-called
research and development to provide representation. device is temporarily taken out for
"Monitor" function.
plants with state-of-the-art technology. maintenance.
The behaviour of all objects in the
ECS/ProcessExpert utilizes the advanced
controller can be monitored at Custom design
control techniques that FLSmidth has • Process customized "abnormal The technologies
different levels of detail for easy
developed over the last 40 years. situation management" • M
 PC (Model Predictive Control):
troubleshooting of the controller
The result is a suite of customizable A multi-input, multi-output controller
• Process customized operation
technologies that allow plant operators that handles process dynamics and in-
For a realistic test of the controller, the objective
to tailor functions to meet their unique teractions. MPC performs optimization
designer will often use the built-in PLC • Priority management of the objectives calculations to drive the measurements
requirements – and make it possible for
communication drivers of to predefined targets or ensure they
plants to design their own solutions.
ECS/ProcessExpert to perform real-time
Each of the process control applications Simulated testing remain within a set band limit
test with the current process values.
in ECS/ProcessExpert uses advanced For control system designers in the • Fuzzy logic: Delivers rule-based,
techniques such as model predictive cement industry, ECS/ProcessExpert can intelligent fuzzy control
control and fuzzy logic rules. The system
Easy integration with be seamlessly integrated with the
is designed for operation globally and is
existing control systems real-time cement process simulator
• Kalman filter: A soft sensor that
ECS/ProcessExpert has specific I/O generates readings where signals are
capable of handling a wide range of ECS/CEMulator. Using this simulator as a unavailable or unreliable
drivers for communicating to
challenges, including adaption to plant virtual plant, various process conditions
PLC's like:
upgrades and testing of new solution can be triggered to test the controller
prototypes. • Rockwell Automation behaviour, before the final
(PLC 5/Control Logix) implementation takes place. In fact, all
• Siemens (S5 / S7) new cement-oriented automation
• Schneider developments from FLSmidth are tested
on the ECS/CEMulator for various
difficult conditions, before the solution
is ready for its first site test.
14 15

Eight steps to a successful Customer services

process control solution and support

For equipment to operate The moment FLSmidth begins an FLSmidth offers a wide range FLSmidth’s
reliably and efficiently, it advanced process control project, a of services to help customers remote services
needs to be implemented dedicated project manager is assigned ensure the long-term success • 24-hour hotline: Telephone support
correctly. FLSmidth’s 8 step to coordinate all activities over the of their ECS/ProcessExpert for critical issues anytime.
lifetime of the plant. As the main
implementation model provides investment by boosting
contact for the plant, the project • Remote troubleshooting: Online
the professional support the system’s efficiency
manager is involved in the support for technical issues.
necessary to ensure the system to improve performance,
implementation process right from • Remote engineering: Specialist
meets all requirements and the start, providing the plant with a
utilization and productivity.
assistance for minor engineering
expectations. clear and detailed project plan that With FLSmidth, great service and issues.
contains all the phases, key deadlines, support doesn’t end when a plant’s
project meetings and more. • KPI monitoring: Data analysis and
automation system is fully
report generation provide an up-to
commissioned. Even a highly reliable
Working with the FLSmidth 8 step date overview of all plant processes.
control system benefits from strong
model, the project manager will post commissioning support.
ensure the advanced process control
system delivers reliable performance FLSmidth provides long-term support
as quickly and as smoothly as and remote assistance to help ensure
possible. The model also ensures that efficient operations throughout the
the system is maintained correctly lifetime of the plant.
after implementation – so it continues
to generate top performance for
years to come.

Long-term support for FLSmidth’s 8 step 6. Remote monitoring and FLSmidth provides the introduction, user, specialist and
long-term success implementation process fine-tuning: As the final part of following services expert levels – and special courses
To ensure the lasting performance of the commissioning phase, FLSmidth tailored to the unique requirements
1. Project planning: An FLSmidth makes small adjustments to the • Remote engineering support
the ECS/ProcessExpert control system, project manager prepares a of engineering companies and
system either remotely or onsite . FLSmidth can often troubleshoot
FLSmidth offers to continue to comprehensive, start-to-finish technical centres can also
and make necessary adjustments
evaluate the system and its processes strategy 7. Follow-up visit: After be arranged.
commissioning is complete, from offsite. This approach can be
after commissioning is complete.
2. Client process interviews: FLSmidth visits the site and used for cement plants that don't • Service & migration agreement
FLSmidth technicians visit the site transitions to the service phase of want to invest in a system champion When the plant has an emergency,
ECS/ProcessExpert continually gathers to determine the plant’s control the agreement. and wants FLSmidth to maintain it needs immediate assistance. With
plant data and sends it to the needs.
the advanced control applications. an FLSmidth service and migration
processing centre at FLSmidth’s 8.Establishing long-term support:
3. Application design and process FLSmidth continues to monitor Evaluating a plant’s system remotely agreement, the plant gets both
headquarters. A detailed KPI strategy review: FLSmidth designs the system and analyse KPI saves time and reduces travel costs remote and onsite help to ensure
monitoring report is then generated, the right solution based on the site data,FLSmidth continues to monitor associated with specialist visits. maximum system uptime and
and if this indicates that the plant is visit and interviews. the system and analyze KPI data, optimal plant performance at all
not performing as efficiently as helping to support the system • Training courses
4. Primary system commissioning: times. This makes upgrades simple
possible, FLSmidth in collaboration and ensure that the plant runs as To keep operators on top of
Commissioning is completed and and smooth – and helps secure the
with the plant management can make efficiently as possible. processes and new technologies
the system is implemented and plant’s long-term investments.
adjustments remotely or onsite. monitored onsite . and knowledge, FLSmidth provides
However, if the plant prefers to do training courses for all plant
5. Operator and super-user
the data analysis in-house, FLSmidth staff. Courses are divided into
training: FLSmidth representatives
will send all the necessary data train operators in the new system.
directly to the plant.
 C 09-11 800-113-ENG V1

Copyright © 2014 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations
or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. www.flsmidth.com/pxp