Improving Performance of

Vertical Roller Mills

Using Advanced Process Control and

Real Time Optimization
Steve McGarel Loesche GmbH Germany

Operational Challenges in the Plant

Cost efficient production despite rising energy, labor and material costs Increase throughput and maintain process stability to improve power efficiency

Reduced performance due to different operator philosophies and experience

Optimum use of personnel knowledge capture best practices Highest possible availability of equipment - process and mechanical safety Implement projects with high Return On Investment for new capital spending For Roller Mills, correct product fineness, in a stable process, at high output
Optimize mill operation to lower production cost Provide the plant with consistent feed to improve performance and reduce cost Reduce specific energy use and carbon footprint to support sustainability efforts

Mill Optimization Solution

is a state of the art optimization solution for Loesche Roller Mills

Uses commercial software to benefit from advanced R&D and control technology
Loesche is a mill supplier not a software design company Software platform fully tested and proven in industry projects

Designed using Loesches unique knowledge of roller mill design and operation improves mill efficiency and helps solve operational problems in existing mills - or can be specified for new mill projects

Proven on pilot site to deliver excellent results in terms of

Production rate Energy consumption Vibration reduction Process stability

Real Time Optimization of Vertical Roller Mills

Obstacles and requirements of Vertical Roller Mill process and operation Advantages of mill optimization Solution Description Savings and Benefits to clients
Case Study project

Obstacles to Optimal Operation

Factors affecting stable and efficient operation are changing in real time Raw material characteristic physical size, mineral composition
Affects grindability of feed

Raw material moisture content

Affects dry mass flow of rock as well as drying and grinding capacity

Equipment wear e.g. mill tires

Reduces grinding capacity until mechanical maintenance is performed

Very fast process dynamics requiring constant attention and accurate control moves Optimal operation can only be achieved via advanced process control
Manual operation cannot be continuously effective and accurate Multiple units to monitor and control reduces time to maximize mill performance

Requirements of Vertical Roller Mill Process and Operation

Increase Production in presence of potential limitations
Mill Table Power Mill differential Pressure - Mill fan capacity External recirculation system - Bucket Elevator and other conveyors Drying capacity - Mill outlet temperature

Reduce Product Size (Residue) Variability

Balance throughput with stability of mill competing objectives Rapidly and continually adjust for changes in feed hardness for consistent grinding

Reduce Specific Power Consumption

Reduce variability in the load parameters mill table power, mill delta Pressure, mill fan power Reduce specific power - mill fan & mill table when operating with a fan at full speed consider table power limiting production

Control Scheme Structure Using PID Controller

Error Set Point Comparator Controller Control Output Actuator

PID Controller
Proportional - Integral - Derivative Feedback Control Action

Feedback Element

Sensor Sensor Output Output

Plant

Disturbances

Limitations of PID Loop Control Environment

Each PID has no knowledge of the whole system or other PID loops and no process knowledge is embedded in the control scheme No dynamic capability, no non-linear capability (changing process behavior)
Reactive to the present, very limited capability to consider future effect in the process

Poor with process delay times, noisy signals, large disturbances

Transfers noise to the output and into the process from multiple PID loops

PID tuning is difficult, subjective, requires time and experience, ongoing

Compromise of multiple aspects P,I &D; trade off regulation versus response time

These effects add up over time

Multiple loops acting independently are not optimal and can work against each other Increases variability, decreases output and quality, ultimately increases production cost

Process Control Hierarchy

Optimize Process Performance Model Predictive Control Define production versus quality versus stability Calculate process set points Automatic Loop Performance Ratio Optimize

Feedback PID
Cascade Feed forward (multivariable) Manual Set Points

Automatic

On/Off
Open loop

Manual

Path to Process Optimization

When stabilized, the process can be pushed to the real physical limits

Project Benefit

Manual

Stabilize

Optimize

Advantages of Mill Optimization

Fast process dynamics controlled by high speed solution Multiple variables are tightly controlled over complete mill circuit Competing objectives of throughput, quality and energy use are handled optimally Continuous display of process conditions increases operator confidence Stable automated operation of the Vertical Roller Mills allows operators to focus on the main processes pyro-process, alternative fuels and product quality Improved operation of the Vertical Roller Mills e.g. in raw mill, clinker grinding leads to more stable and efficient operation of the complete cement line

Solution Description Schematic

Model Predictive Control Variable Classes

CVs Controlled Variables
targets for the controller and process e.g. fineness

MVs Manipulated Variables controller adjusted set points sent to the process e.g. feed rate, classifier speed, fan upper and lower limits for variables e.g. vibration, pressure, motor load factors that affect the process but are not in the control matrix structure e.g. feed hardness, feed size, moisture content, roller wear DVs CCVs Constraint Variables DVs Disturbance Variables

MVs

Model Predictive Controller CCVs

CVs

MPC Step Test Response and Prediction Horizons

Step Move

Step Change in Manipulated Variable e.g. Mill Feed Rate

MV

Rise Time Response of Controlled Variable Gain e.g. Mill Motor Power, Delta Pressure Delay Time Current Time History Prediction Horizon CV

Controller Matrix

CV 1 MV 1 MV 2 MV 3
No Model

CV 2

CV 3

CV 4
No Model

No Model

Pairs of variables define process interactions Process response is captured in the controller

Example of Solution Variables

Classifier Speed (MV)

Fan Speed (MV)

15 second controller cycle Total Feed (MV)

Fineness (CV) Outlet Temp (CV)

60 sec. residue predictions compared to 1 hour lab result

Feed Hardness (DV) Feed Moisture (DV) Feed Blend (DV) MV Manipulated Variable

Water Flow (MV) Roller Pressure (MV)

Diff. Pressure (CCV) Vibration (CCV) Motor Load (CCV)

Roller Wear (DV) Weather Conditions (DV)

CV Controlled Variable

CCV Constraint Variable DV Disturbance Variable

~ 70 variables on a mill circuit

Optimizer uses a sub-set of variables for efficient control

Implementing Control Using All Recommended Variables

Operators normally control multiple units raw mill, cement mill, coal mill, kiln or some combination

Customer may not be using roller pressure or water sprays for control too many variables to deal with on a frequent basis
Roller mill is deliberately cut back to allow focus on full process

increases performance level and allows hands off operation

Operate with best possible performance all the time

System Hardware Architecture

Client

Server

Case Study Project In Operation

Case Study Project Steps

Historical data analyzed to determine baseline performance Determine important variables for the project mill Step tests of main variables on site to capture mill response Controller matrix constructed and connected to PLC network Model predictions checked in Read - Only mode Variables activated in Read-Write mode one by one and tuned Multiple variables activated in control mode and interaction tuned Run time accumulated in full closed loop control to fine tune

Off Line Data Analysis

Operational History Process Variability

Controller Matrix Developed from Process Knowledge

Controller Set Up Screen Shot

Coefficent / Rank: Determination of priorities 1. Residue 2. Mill differential pressure 3. Increase of material feed Frustum = Soft Constraints

Constraints: Limitations for CVs and MVs CVs may violate hard constraints, but MVs may not

Operator Screen

Key Performance Indicators (KPIs

Applications Manager Detail

Project Timeline and Major Steps

Development and implementation in 2-3 calendar months Close teamwork with the customer Operator integration into implementation process Consultation to define improvements and improve controller Final meeting after evaluation of results Overall project duration approximately 4 months

28

by LOESCHE GmbH

Benefits Comparison Before and After Project

Original Installation Contract condition (2006):

Specific power consumption 21,2 kWh/t, Product rate 480 t/h

+ 25 tph over 5 years Mechanical and operation changes

Optimization Project Starting condition (2011):

Specific power consumption 15,8 kWh/t , Product rate 505 t/h

Optimization Project Evaluation condition (June 2011):

Specific power consumption 15,2 kWh/t, Product rate 528 t/h

+ 23 tph over 3 months

Benefits Summary
Increase throughput of 6 % Energy savings of 5 %

Reduced mill vibration by 17 % (1.04 mm/s)

Controller utilization greater than 90 % Improved stability of the circuit and variability of raw meal residue Operator freed up to better monitor kiln performance Reduced CO2 emissions from plant (produces own electric power) Return on Investment less than 12 months

Total Fresh Feed Before and After Project

Note feed rate changes

Power Consumption Before and After

Mill Diff Pressure Before and After

Mill Vibration Before and After

Maximum Maximum

Average

Conclusion
is a state of the art optimization solution for Loesche Roller Mills

improves mill efficiency and helps solve operational problems in existing mills - or can be specified for new mill projects

Proven to deliver excellent results in terms of

Production rate Energy consumption Vibration reduction Process stability

THE END ! Thank You