BeST to optimise cement mill

October 2001 System Integration & Control Systems Design

BeST South Africa, a supplier of integrated and optimised control solutions, has recently secured a contract to optimise the control of the cement kiln at Dwaalboom, a large integrated cement factory based in the Northern Province.

This contract is a result of the very successful control and optimisation projects previously done at the Dwaalboom and PPC Limeacres site. A lime kiln control-optimising project is currently underway at PPC Limeacres.

When PPC Cement contracted BeST to provide the kiln perfecter for optimised control of the cement kiln at Dwaalboom, the opportunity was used to provide the infrastructure for a model based predictive controller for the cement mill as well. As with the kiln, there exists a need to optimise the mill in terms of production, quality and efficiency within constraints, and like the kilns, the mill is a classical example of a nonlinear multivariable process.

This is not a simple task due to the nonlinear, multivariable nature of the mill, as well as other process problems such as slow response times, limited process measurements, diffused plug flow, and the fact that the processes can be construed as chaotic. The optimal advanced control system supplied is a nonlinear, multivariable, model-based predictive (MPC) controller that uses as its foundation a unique blend of powerful technology incorporating model-based predictive control and expert systems.

The core technology is the optimising model-based predictive control engine (Pavilion's Process Perfecter) which allows for the nonlinear steady state modelling of the process using neural networks, and the coupling of this to a model-based predictive dynamic controller. A surrounding intelligent expert system 'KICS Wrapper' is used to monitor the instruments and perform intelligent signal processing to prepare the signals to be fed to the controller. The result is an extremely robust controller that adapts to the plant instrumentation failures or uncertainties. This allows production staff to optimise the mill according to various economic and operational strategies.

The new controller will allow for production and efficiencies to be maximised, whilst keeping various quality, and other process variables within constraints. (The picture shows a PPC mill).

BeST SA

(011) 884 0510

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