Supervisory-plus-regulatory control design for efficient operation of industrial furnaces

A two-level system engineering design approach to integrated control and supervision of industrial multi-zone furnaces has been elaborated and tested. The application case study is the three-zone 25 MW RZS furnace plant at Skopje Steelworks. The integrated control and supervision design is based on combined use of general predictive control optimization of set-points and steady-state decoupling,at the upper level, and classical two-term laws with stady-state decouling, at the executive control level. This design technique exploits the intrinsic stability of thermal processes and makes use of constrained optimization, standard non-parametric time-domain process models, identified under operating conditions, using truncated k-time sequence matrices, controlled autoregressive moving average models. Digital implementations are sought within standard computer process control platform for practical engineering and maintenance reasons

Dynamic simulation of industrial grinding circuits : mineral liberation, advanced process control, and real-time optimisation

Étant donné que les minéraux apparaissent fréquemment dans des associations complexes dans la nature, la libération minérale est un aspect clé du traitement de minerais et celle-ci est accomplie par comminution. Cette opération est certainement l’une des plus importantes, mais aussi des plus coûteuses dans l’industrie. La réussite globale d’une usine dépend souvent de la performance du circuit de broyage car il existe un compromis pour atteindre la taille des particules libérant les minéraux ciblés afin d’obtenir des concentrés de haute pureté tout en ayant de faibles coûts d’opération, lesquels sont largement influencés par la consommation énergétique. Dans les années récentes, les entreprises ont été confrontées à des objectifs de performance plus exigeants, une concurrence accrue sur les marchés, et des réglementations environnementales et de sécurité plus strictes. D’autres défis supplémentaires sont inhérents aux circuits de broyage, par exemple les réponses non linéaires, le niveau élevé d’intercorrélation entre les variables et les recirculations de matière. Les problèmes ci-dessus soulignent la pertinence d’avoir des systèmes de contrôle et d’optimisation adéquats pour lesquels les praticiens profitent de plus en plus des approches basées sur des modèles pour y faire face de façon systématique. La modélisation et la simulation sont des outils puissants ayant des avantages significatifs tels que les faibles coûts, les temps requis pour réaliser des expériences relativement courts et la possibilité de tester des conditions opérationnelles extrêmes ainsi que différentes configurations des circuits sans interrompre la production. De toute évidence, la qualité des résultats sera aussi bonne que la capacité du modèle à représenter la réalité, ce qui souligne l’importance d’avoir des modèles précis et des procédures de calibrage appropriées, un sujet fréquemment omis dans la littérature. Un autre aspect essentiel qui n’a pas été rapporté est l’intégration efficace de la libération minérale aux systèmes de contrôle et d’optimisation de procédés. Bien qu’il s’agisse d’une information clé directement liée aux performances de l’étape de concentration, la plupart des stratégies se concentrent exclusivement sur la taille de particule du produit. Ceci est compréhensible étant donné qu’il est impossible de mesurer la distribution de libération présentement. Basée sur une librairie de simulation d’usines de traitement des minerais déjà existante, cette recherche aborde lesdits problèmes en (1) développant un modèle de libération minérale visant à coupler les étapes de broyage et de concentration ; (2) programmant et validant par calibrage un modèle phénoménologique de broyeur autogène/semi-autogène (BA/BSA), nécessaire pour compléter la librairie de simulation ; (3) couplant un simulateur de circuit de broyage à un procédé de concentration avec le modèle de libération, et (4) développant un système de contrôle et d’optimisation qui considère explicitement des données de libération minérale pour évaluer les avantages économiques. Les principaux résultats confirment que le modèle de libération est capable de reproduire avec précision des distributions de libération minérale couramment observées dans l’industrie. Cependant, si les données de calibrage correspondent à un point d’opération unique, la validité pourrait être limitée aux régions voisines proches. Le problème de caractériser l’évolution de la libération minérale aux diverses conditions d’opération ainsi qu’aux régimes transitoires reste à être abordé. Le modèle de libération s’est aussi révélé utile pour coupler des circuits de broyage avec des procédés de concentration, en particulier pour une unité de flottation. Quant au modèle de BA/BSA, celui-ci peut capturer le régime statique ainsi que la dynamique d’un broyeur réel et conjointement avec le reste des équipements dans la librairie de simulation, des circuits de broyage industriels. Ceci a été confirmé par le calibrage à partir des données d’opération d’une usine et des tests en laboratoire, tout en suivant une procédure systématique, contribuant aussi au sujet de l’établissement de méthodologies de calibrage standardisées. Pour terminer, les expériences concernant la stratégie de contrôle et d’optimisation basée sur la libération minérale suggèrent que l’utilisation de cette information peut améliorer la performance globale des circuits de broyage-séparation en réagissant aux variations des caractéristiques de libération, qui à leur tour influencent l’efficacité de séparation. L’étude de cas réalisé révèle que cela peut entraîner une augmentation du débit massique et de la teneur du concentré, de la récupération des métaux et des revenus de l’ordre de +0.5%, +1%, +1% et +5%, respectivement, par rapport au cas où ces informations sont omises.As minerals frequently appear in complex associations in nature, mineral liberation is one of the most relevant aspects in ore processing and is achieved through comminution. This operation is one of the most important, but also one of the most expensive ones in industry. The global efficiency of a plant often depends on the performance of the grinding circuit, since there is a compromise to achieve the particle size liberating the targetted minerals in order to obtain high purity concentrates while maintaining low operating costs, which are largely influenced by the energy consumption. In recent years, companies have been facing more demanding performance targets, stronger competition, and more stringent environmental and safety regulations. Additional challenges are inherent to the grinding circuits themselves, e.g. the nonlinear responses, high degree of intercorrelation of the different variables, and material recirculations. The abovementioned issues highlight the relevance of adequate process control and optimisation, and practitioners rely more often on model-based approaches in order to face them systematically. Modeling and simulation are powerful tools with significant advantages such as low costs, required times for conducting experiments are relatively short, and the possibility of testing extreme operational conditions as well as different circuit configurations without disrupting production. Evidently, the quality of the results will only be as good as the model capacity to represent the reality, which emphasises the relevance of having precise models and proper calibration procedures, the latter being a topic frequently omitted in the literature. Another crucial aspect that has not been reported yet is the effective integration of mineral liberation in control and optimisation schemes. Although it is a key piece of information directly related to the performance of the concentration stage, most strategies focus exclusively on the particle size. This is understandable given that it is currently impossible to measure the liberation distribution online. Based on an existing mineral processing plant simulation library, this research addresses these problems by (1) developing a mineral liberation model aiming at linking the grinding and concentration stages; (2) programming a phenomenological autogenous/semiautogenous (AG/SAG) mill model, required to complement the simulation toolbox, and validating it through calibration; (3) coupling a grinding circuit simulator to a concentration process by means of the liberation model, and (4) developing a plantwide control and optimisation scheme considering mineral liberation data explicitly to evaluate the economic benefits. The main results confirm that the liberation model is capable of reproducing accurately mineral distributions observed in industry. If calibration data correspond to a single operating point, its validity may however be limited to the close neighbourhood. Characterising the evolution of mineral liberation in different operating conditions and transient states remains to be addressed. The liberation model proved to be equally useful in coupling grinding circuits with concentration processes, specifically for flotation. As for the AG/SAG mill model, it can capture the steady state and dynamic behaviour of an actual device and, along with the rest of pieces of equipment in the simulation toolbox, of industrial grinding circuits. This was confirmed through calibration from plant data and laboratory testwork following a systematic procedure, contributing to the endeavour of establishing standard calibration methodologies. Lastly, the results of the designed control and optimisation scheme suggest that using liberation data for control and real-time optimisation can improve the overall performance of grinding-separation circuits by reacting to variations in the liberation characteristics, which in turn influence the concentration performance. The case study reveals that doing so can lead to increases in the concentrate mass flow rate and grade, metal recovery, and global profits in the order of +0.5%, +1%, +1%, and +5%, respectively, compared to the case omitting this information

A Control Evaluation on a Slurry-Filled Sump

Sump can be definedas a reservoir which is normally located at the downstream of a process, from which water is pumped where solids accumulates. Sump is a system which faces instability due to its dynamic behaviors. Application of control strategies to the sump might add some advantages in handling the sump, where in some process, sumpplays a significant role especiallywhen it involves in a process that have highly hazardous stage. This project studies generally observe the behavior of the sump by adapting control type such as the feedback, Smith predictor, feedforward, and cascade control. In addition, the sump is adaptedwith a neurocontrol from Neural Network Control strategies. The neurocontrol used is the NARMA-L2 controller. The variation of simulation have resulted in a way that majority of the controller are at highest performance when the percentage of solids in is 80%. The application of neurocontrol to the system somehow does not meet the target due to high error that the controller sustained. However, the neurocontrol can be enhanced more by data training and this is recommended for further researchby using other neurocontrol that is available in the Neural Networkcontrol strategies

Technology 2002: the Third National Technology Transfer Conference and Exposition, Volume 1

The proceedings from the conference are presented. The topics covered include the following: computer technology, advanced manufacturing, materials science, biotechnology, and electronics

System modelling and control

Not Availabl

Development of a tube ball mill mathematical model for mill condition and safety monitoring

The PhD research project is to examine if it is possible to minimize the mill faults and fires in the Tube Ball mill operation by using a model based approach. The research outcome proves that the risks of mill fault can be monitored and alerted by implementing the model based on-line condition monitoring software that developed through the PhD project. Coal fired power stations nowadays regularly use coal with higher volatile contents and Biomass materials to satisfy the government regulations on sustainable and renewable energy. This greatly increases the risks of explosions or fires in milling plants. However, there are no acceptable measurement methods available at the present and it is difficult to identify if there will be a fire in the mill. Therefore, the project is carried out from the study mill mathematical model to mill condition monitoring. Monitoring the mill operation conditions only based on currently available on-site measurement without requiring any extra hardware is a cost effective solution and will pose a great challenge. A mathematical model of coal mills is developed using computational intelligent algorithms for prediction of potential mill faults

Technology 2003: The Fourth National Technology Transfer Conference and Exposition, volume 2

Proceedings from symposia of the Technology 2003 Conference and Exposition, Dec. 7-9, 1993, Anaheim, CA, are presented. Volume 2 features papers on artificial intelligence, CAD&E, computer hardware, computer software, information management, photonics, robotics, test and measurement, video and imaging, and virtual reality/simulation

Advances in Condition Monitoring, Optimization and Control for Complex Industrial Processes

The book documents 25 papers collected from the Special Issue “Advances in Condition Monitoring, Optimization and Control for Complex Industrial Processes”, highlighting recent research trends in complex industrial processes. The book aims to stimulate the research field and be of benefit to readers from both academic institutes and industrial sectors

XVIII International Coal Preparation Congress

Changes in economic and market conditions of mineral raw materials in recent years have greatly increased demands on the ef fi ciency of mining production. This is certainly true of the coal industry. World coal consumption is growing faster than other types of fuel and in the past year it exceeded 7.6 billion tons. Coal extraction and processing technology are continuously evolving, becoming more economical and environmentally friendly. “ Clean coal ” technology is becoming increasingly popular. Coal chemistry, production of new materials and pharmacology are now added to the traditional use areas — power industry and metallurgy. The leading role in the development of new areas of coal use belongs to preparation technology and advanced coal processing. Hi-tech modern technology and the increasing interna- tional demand for its effectiveness and ef fi ciency put completely new goals for the University. Our main task is to develop a new generation of workforce capacity and research in line with global trends in the development of science and technology to address critical industry issues. Today Russia, like the rest of the world faces rapid and profound changes affecting all spheres of life. The de fi ning feature of modern era has been a rapid development of high technology, intellectual capital being its main asset and resource. The dynamics of scienti fi c and technological development requires acti- vation of University research activities. The University must be a generator of ideas to meet the needs of the economy and national development. Due to the high intellectual potential, University expert mission becomes more and more called for and is capable of providing professional assessment and building science-based predictions in various fi elds. Coal industry, as well as the whole fuel and energy sector of the global economy is growing fast. Global multinational energy companies are less likely to be under state in fl uence and will soon become the main mechanism for the rapid spread of technologies based on new knowledge. Mineral resources will have an even greater impact on the stability of the economies of many countries. Current progress in the technology of coal-based gas synthesis is not just a change in the traditional energy markets, but the emergence of new products of direct consumption, obtained from coal, such as synthetic fuels, chemicals and agrochemical products. All this requires a revision of the value of coal in the modern world economy